Roller shutter door controller
By designing a roller shutter door controller that includes output connection terminals and multiple detection units, the problem of roller shutter doors failing to open and close normally due to abnormal power supply was solved, achieving precise control and stable operation, and ensuring the normal operation of roller shutter doors in emergency situations.
Patent Information
- Application Number
- CN202520344697.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-01
- Publication Date
- 2026-01-27
- Estimated Expiration
- 2035-03-01
AI Technical Summary
The roller shutter door could not be opened or closed normally due to an abnormal power supply system, affecting its operation and causing safety hazards and operational instability.
Design a roller shutter door controller, comprising a housing, a control module, a power supply, and a backup power supply. The housing has output connection terminals that connect to the three-phase power supply, the motor circuit, and the roller shutter door position feedback circuit. The control module includes a roller shutter door position detection unit, a phase commutation control unit, a phase detection unit, and a load current detection unit, used to accurately control the roller shutter door position and motor operation, ensuring motor stability and system reliability.
It improves the accuracy of roller shutter door position control and system reliability, avoids safety hazards, realizes automated control and stable operation of motor, and ensures normal operation of roller shutter door in emergency situations, thereby enhancing the system's emergency response capabilities.
Smart Images
Figure CN223843584U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of roller shutter door control, and more particularly to a roller shutter door controller. Background Technology
[0002] Roller shutters are widely used in general industrial and commercial applications, typically for controlling the opening and closing of wider doors. When integrated with fire protection systems, they can effectively prevent the spread of fire, making automatic control of roller shutters increasingly important. Roller shutters generally use three-phase motors, and opening and closing are achieved by controlling the forward and reverse rotation of the motor.
[0003] Due to its structure, roller shutter doors are prone to problems opening and closing due to abnormalities in the power supply system during the rolling process, which affects the normal operation of the roller shutter door. Utility Model Content
[0004] To alleviate the problem of abnormal power supply affecting the normal operation of roller shutter doors, this application provides a roller shutter door controller.
[0005] This application provides a roller shutter door controller, which adopts the following technical solution:
[0006] A roller shutter door controller, comprising:
[0007] The housing is equipped with output connection terminals, which are respectively connected to a three-phase power supply, a motor circuit, and a roller shutter door position feedback circuit.
[0008] The control module is located inside the housing. The control module includes a roller shutter position detection unit, a phase commutation control unit, a phase detection unit, and a load current detection unit. The roller shutter position detection unit is connected to the roller shutter door position feedback line and is used to detect the position of the roller shutter door. The phase commutation control unit is connected to the three-phase power supply and is used to control the motor to rotate forward / reverse. The phase detection unit is connected to the three-phase power supply and is used to detect the phase sequence of the three-phase power supply. The load current detection unit is connected to the motor circuit and is used to detect the motor current.
[0009] A power supply, located inside the housing and connected to the control module, is used to provide power to the control module.
[0010] A backup power supply, located inside the housing and connected to the control module, is used to provide power to the control module when the main power supply is abnormal.
[0011] By adopting the above technical solutions, the output connection terminals on the outer casing facilitate connection to the three-phase power supply, motor circuit, and roller shutter door position feedback circuit, which is beneficial for wiring and maintenance. The roller shutter door position detection unit within its control module can accurately determine the roller shutter door position, improving position control accuracy and system reliability, and avoiding safety hazards; the phase reversing control unit can flexibly control the forward and reverse rotation of the motor, realizing the automation of the roller shutter door's lifting and lowering operation and meeting various usage needs; the phase detection unit ensures the correct phase sequence of the three-phase power supply, preventing motor runaway and stalling, and enhancing motor operating stability; the load current detection unit can detect the motor current, preventing the motor from burning out due to high current and strengthening motor protection. Furthermore, the power supply provides a basic guarantee for the normal operation of the system, and the backup power supply continues to supply power when the power supply is abnormal, ensuring the normal operation of the system. Especially in emergencies such as power outages, it can ensure the normal operation of the roller shutter door, improving the system's reliability and emergency handling capabilities, and providing strong support for the safe and stable operation of the roller shutter door.
[0012] Preferably, the connection terminals on the housing are also connected to a fire alarm controller to receive fire alarm signals sent by the fire alarm controller, and to control the roller shutter door to rise and fall to a preset position when the fire alarm signal sent by the fire alarm controller is received.
[0013] By adopting the above technical solution, the connection terminals on the outer casing are connected to the fire alarm controller, which enhances the system's integration and compatibility. This allows the roller shutter door controller to be better integrated into the building's fire protection system. When a fire alarm signal is received, it can control the roller shutter door to rise and fall to a preset position, effectively isolating the fire area, buying valuable time for personnel evacuation, and protecting the safety of people and property.
[0014] Preferably, the roller shutter positioning detection unit includes multiple detection lines, which are used to detect the switching status of the IO1 port; when the roller shutter door is in operation, the limit switch with roller shutter position is turned on, and IO1 is at a low level; the limit switch without roller shutter position is turned off, and the voltage of IO1 is at a high level; the control module determines the position of the roller shutter door by detecting the level status of the IO ports connected to the multiple limit switches.
[0015] By adopting the above technical solution, the roller shutter position detection unit is used for switch status detection. It can accurately determine the level status of the IO port and accurately determine the position of the roller shutter door, thereby improving the accuracy and reliability of roller shutter door position detection.
[0016] Preferably, the phase switching control unit includes relays K1 and K2, which control the connection sequence of the three-phase power supply (A, B, and C) to the motor. When relays K1 and K2 are not activated, phase A of the three-phase power supply reaches position AC3 via K2, phase B reaches position AC2, and phase C reaches position AC1 via K2. When relays K1 and K2 are activated, phase A of the three-phase power supply reaches position AC1 via K1, phase B reaches position AC2, and phase C reaches position AC3 via K2, thereby realizing the forward / reverse rotation of the motor and controlling the raising and lowering of the roller shutter door.
[0017] By adopting the above technical solution, the commutation control circuit includes relays K1 and K2, which are used to control the connection sequence of the ABC three-phase power supply and the motor, thereby achieving effective control of the motor's forward and reverse rotation, and thus flexibly controlling the raising and lowering of the roller shutter door. When relays K1 and K2 are in different states, the connection positions of the three-phase power supply will change accordingly. This simple and effective control method allows the motor to easily switch between forward and reverse rotation, thereby realizing the opening and closing operation of the roller shutter door.
[0018] Preferably, the phase detection unit includes three zero-crossing detection lines, which are respectively connected to the A, B, and C live wires of the three-phase power supply. For each of the three phases A, B, and C, the zero-crossing detection line includes a live wire L, a neutral wire N, a rectifier bridge D1, a current-limiting resistor R4, an optocoupler IC1, and a pull-up resistor R5. The signal between L and N is an AC signal, which is converted into a full-wave signal by the D1 rectifier bridge. When the full-wave signal voltage is greater than the optocoupler's conduction voltage, the optocoupler output terminal is turned on, and the Ua terminal is at a low level. When the full-wave signal voltage is less than the optocoupler's conduction voltage, the optocoupler output terminal is turned off, and the Ua terminal is at a high level. The zero-crossing detection lines are used to perform zero-crossing pulse detection on the three-phase power supply A, B, and C respectively. The signal Ua enters the control module, and the control module realizes phase detection of the three-phase power supply based on the signal Ua.
[0019] By adopting the above technical solution, the three zero-crossing detection circuits of the phase detection unit target the A, B, and C live wires of the three-phase power supply respectively. Through the cooperation of components such as the live wire L, neutral wire N, rectifier bridge D1, current-limiting resistor R4, optocoupler IC1, and pull-up resistor R5, the AC signal between L and N is converted into a full-wave signal by the rectifier bridge. Based on the relationship between the full-wave signal and the optocoupler's conduction voltage, corresponding high and low level signals Ua are generated. This zero-crossing detection circuit performs zero-crossing pulse detection on the three-phase power supply, providing an effective detection signal for the control module.
[0020] Preferably, the load current detection unit includes AC Hall sensors H1, H2, and H3. The connecting lines of the motor circuit pass through the AC Hall sensors respectively, and the output of the AC Hall sensors is connected to the analog port of the control module to realize the detection of load current by the control module.
[0021] By adopting the above technical solution, the load current detection unit uses AC Hall sensors H1, H2, and H3, and the motor circuit connection lines pass through these sensors respectively. At the same time, the output of the sensors is connected to the analog port of the control module. The use of AC Hall sensors provides a reliable means for accurate measurement of load current, and can monitor the motor's operating current in real time, making it easy to detect any abnormalities that may occur during motor operation, thereby achieving effective detection of load current.
[0022] Preferably, the control module further includes a motor connection line monitoring unit, which includes DIO1, AD1, and AD2. DIO1 is connected to the switch output port of the control module, and AD1 and AD2 are connected to the analog input port of the control module. When the motor is not working, the output voltage of DIO1 is output to AD1 and AD2 through the internal circuit of the motor. The control module determines whether there is an open circuit in the motor connection line by monitoring the voltage of AD1 and AD2.
[0023] By adopting the above technical solution, the motor connection line monitoring unit includes DIO1, AD1, and AD2. By connecting DIO1 to the digital output port of the control module, and AD1 and AD2 to the analog input ports of the control module, an effective monitoring system is formed. When the motor is not working, the output voltage of DIO1 is transmitted to AD1 and AD2 through the motor's internal circuitry. This allows the control module to determine whether the motor connection line is open by monitoring the voltages of AD1 and AD2. This monitoring method can accurately detect open circuits in the motor connection line, identify potential line faults in advance, and prevent the motor from malfunctioning due to line breaks, thus ensuring the normal operation of the motor.
[0024] Preferably, the control module further includes a status display unit, which includes a buzzer and a status indicator light. When the control module detects an abnormality in the three-phase power supply, an abnormality in the line connected to the motor, or an abnormality in the motor operation, the buzzer sounds and the status indicator light illuminates.
[0025] By adopting the above technical solution, the status display unit includes a buzzer and a status indicator light. When the control module detects an abnormality in the three-phase power supply, an abnormality in the motor connection line, or an abnormality in the motor operation, the buzzer sounds and the status indicator light illuminates, providing an intuitive abnormal status prompt, which makes it easy for users or maintenance personnel to quickly detect system faults.
[0026] Preferably, the roller shutter door controller further includes a manual control module, which is connected to the control module and is used to handle button operations and status prompts.
[0027] By adopting the above technical solution, the manual control module is connected to the control module and is specifically used to handle button operations and status prompts, providing users with a means to directly operate the roller shutter door. Through button operations, users can easily perform various controls on the roller shutter door, such as opening, closing, and stopping, meeting users' manual operation needs for the roller shutter door in different scenarios. At the same time, status prompts can also be provided, allowing users to intuitively understand the current status of the roller shutter door, improving user operation convenience and system user-friendliness.
[0028] In summary, this application includes at least the following beneficial technical effects:
[0029] 1. The output connection terminals on the casing facilitate connection to three-phase power supplies, motor circuits, and roller shutter door position feedback circuits, simplifying wiring and maintenance. The roller shutter door position detection unit within its control module accurately determines the roller shutter door's position, improving position control precision and system reliability, and preventing safety hazards. The phase-reversing control unit flexibly controls the motor's forward and reverse rotation, automating the roller shutter door's lifting and lowering operation to meet various usage needs. The phase detection unit ensures the correct phase sequence of the three-phase power supply, preventing motor runaway and stalling, and enhancing motor operational stability. The load current detection unit detects the motor's operating current, preventing motor burnout due to excessive current and strengthening motor protection. Furthermore, the power supply provides a fundamental guarantee for the system's normal operation, while the backup power supply continues to provide power when the main power supply is abnormal, ensuring normal system operation. Especially in emergencies such as power outages, it ensures normal roller shutter door operation, improving system reliability and emergency response capabilities, and providing strong support for the safe and stable operation of the roller shutter door. Attached Figure Description
[0030] Figure 1 This is a schematic diagram of the overall structure of a roller shutter door controller provided in an embodiment of this application;
[0031] Figure 2 This is a circuit diagram of a roller shutter positioning detection unit provided in an embodiment of this application;
[0032] Figure 3 This is a circuit diagram provided in an embodiment of this application;
[0033] Figure 4 This is a circuit diagram of a phase detection unit provided in an embodiment of this application;
[0034] Figure 5 This is a schematic diagram of the structure of a control module provided in an embodiment of this application;
[0035] Figure 6 This is a schematic diagram illustrating the connection between a roller shutter door controller and a fire alarm controller, as provided in an embodiment of this application.
[0036] Figure 7 This is a schematic diagram of another control module provided in an embodiment of this application;
[0037] Figure 8 This is a schematic diagram of the overall structure of another roller shutter door controller provided in this application embodiment.
[0038] Reference numerals: 100, Housing; 200, Control module; 210, Roller shutter position detection unit; 220, Phase switching control unit; 230, Phase detection unit; 240, Load current detection unit; 250, Motor connection line monitoring unit; 260, Status display unit; 261, Buzzer; 262, Status indicator light; 300, Power supply; 400, Backup power supply; 500, Fire alarm controller; 600, Manual control module; 610, Button unit; 620, Status indication unit; 630, Sound unit; 640, Communication unit. Detailed Implementation
[0039] The following is in conjunction with the appendix Figure 1 -Appendix Figure 8 This application will be described in further detail.
[0040] This application discloses a roller shutter door controller.
[0041] Example 1
[0042] Reference Figure 1 A roller shutter door controller includes: a housing 100, a control module 200, a power supply 300, and a backup power supply 400.
[0043] Specifically, the housing 100 is equipped with output connection terminals, which are respectively connected to the three-phase power supply, the motor circuit, and the roller shutter door position feedback circuit. More specifically, the housing 100 is made of high-strength engineering plastic or metal materials, such as ABS plastic or aluminum alloy, providing good physical protection for the internal components and resisting a certain degree of impact, compression, and dust intrusion. The output connection terminals can be pluggable terminals, installed on one side of the housing 100. Each terminal is clearly labeled, corresponding to the three-phase power supply (L1, L2, L3), the motor circuit (U, V, W), and the roller shutter door position feedback circuit (such as high, medium, and low position feedback). This pluggable design facilitates wiring and maintenance while ensuring connection stability.
[0044] The control module 200 is located inside the housing 100. The control module 200 includes a roller shutter position detection unit 210, a phase commutation control unit 220, a phase detection unit 230, and a load current detection unit 240. The roller shutter position detection unit 210 is connected to the roller shutter door position feedback line and is used to detect the position of the roller shutter door. The phase commutation control unit 220 is connected to the three-phase power supply and is used to control the motor to rotate forward / reverse. The phase detection unit 230 is connected to the three-phase power supply circuit and is used to detect the phase sequence of the three-phase power supply. The load current detection unit 240 is connected to the motor circuit and is used to detect the operating current of the motor.
[0045] More specifically, see Figure 2 The roller shutter position detection unit 210 includes multiple detection lines. Each detection line includes limit switches, wiring plugs JP1 and JP2, and current-limiting resistors R1, R2, and R3. Each limit switch is connected to the control module 200 via a wire. R2 and R3 are connected to the IO1 port of the control module 200 to detect the switch status of the IO1 port. When the roller shutter is in operation, the limit switch with the roller shutter position is turned on, the limit switch corresponding to JP1 is short-circuited, and IO1 is at a low level. The limit switch without the roller shutter position is turned off, the limit switch corresponding to JP1 is turned off, and the voltage of IO1 is at a high level. The control module 200 determines the position of the roller shutter by detecting the level status of the IO ports connected to the multiple limit switches.
[0046] More specifically, the limit switch can be a small micro limit switch, and the wiring plugs can be common pin header and nut type plugs JP1 and JP2. R1 can be a 10KΩ resistor, and R2 and R3 can be 1KΩ resistors. The resistor accuracy is selected as ±5%, which meets the basic requirements of the circuit for resistance value, effectively limiting current and protecting the I / O ports of the control module 200. The control module 200 can use a common 8-bit microcontroller, such as the ATmega328P, which has abundant I / O ports and can meet the needs of connecting multiple limit switches.
[0047] Circuit connection: One end of each limit switch is connected to the power ground (GND), and the other end is connected to the first end of JP1 through a wire. The second end of JP1 is connected to the other end of the limit switch through a wire (i.e., in parallel with the limit switch) to achieve the short circuit function. The third end of JP1 is connected to the first end of JP2 through a wire. The fourth end of JP1 is connected to the second end of JP2. The third end of JP2 is connected to one end of R2. The fourth end of JP2 is connected to one end of R3. The other end of R3 is grounded (GND). The other end of R2 is connected to one end of R1. The other end of R1 is connected to the power supply VCC (e.g., 5V). The connection end of R2 and R1 serves as the signal output end, connected to the IO1 port of the control module 200.
[0048] The operating principle of the roller shutter positioning detection unit 210 is as follows: When the roller shutter door reaches a specific position, the corresponding limit switch is activated. At this time, the limit switch corresponding to JP1 is short-circuited, and current flows to ground through R2 and R3. Due to the voltage division effect of R2 and R3, the voltage at the IO1 port approaches ground potential, exhibiting a low level. When the roller shutter door has not reached this position, the limit switch is deactivated, and the limit switch corresponding to JP1 is also in the deactivated state. At this time, the power supply VCC is pulled up through R1, causing the voltage at the IO1 port to approach VCC, exhibiting a high level.
[0049] See Figure 3 1. The commutation control circuit includes relays K1 and K2, which control the connection sequence of the three-phase power supply (A, B, and C) to the motor. When relays K1 and K2 are not activated, phase A power flows through K2 to position AC3, phase B power flows to position AC2, and phase C power flows through K2 to position AC1. When relays K1 and K2 are activated, phase A power flows through K1 to position AC1, phase B power flows to position AC2, and phase C power flows through K2 to position AC3, thus enabling the motor to rotate forward / reverse, thereby controlling the raising and lowering of the roller shutter door. More specifically, ordinary electromagnetic relays can be used, such as the Songle SRD-05VDC-SL-C relay.
[0050] More specifically, the relay can be the Songle SRD-05VDC-SL-C relay, and the driver chip can be the ULN2003 chip. Since the microcontroller's I / O port driving capability is limited, a driver chip is needed to control the relay. The ULN2003 chip can provide a large drive current, can drive multiple relays simultaneously, and has a back EMF suppression function to protect the microcontroller. A common 8-bit microcontroller, such as the STC89C52, can be used, as it has abundant I / O port resources, enabling convenient control of the relay's operation.
[0051] Circuit Connections: One end of the coils of relays K1 and K2 is connected to a +5V power supply, and the other end is connected to two output pins (e.g., OUT1 and OUT2) of the ULN2003 chip, respectively. The input pins (e.g., IN1 and IN2) of the ULN2003 chip are connected to two I / O ports (e.g., P1.0 and P1.1) of the microcontroller, respectively. Phase A power is connected to the common terminal (COM) of relays K1 and K2. When relays K1 and K2 are not activated, the normally open contact (NO) of K2 is connected to position AC3; when relays K1 and K2 are activated, the normally open contact (NO) of K1 is connected to position AC1. Phase B power is directly connected to position AC2 without relay switching. Phase C power is connected to the common terminal (COM) of relay K2. When relays K1 and K2 are not activated, the normally open contact (NO) of K2 is connected to position AC1; when relays K1 and K2 are activated, the normally open contact (NO) of K2 is connected to position AC3. The three terminals of the motor are connected to positions AC1, AC2, and AC3, respectively.
[0052] The implementation principle of the phase commutation control circuit is as follows: Relay inactive state: When the microcontroller's P1.0 and P1.1 pins output a low level, the OUT1 and OUT2 pins of the ULN2003 chip are at a high level, and the coils of relays K1 and K2 are not energized, remaining inactive. At this time, phase A power reaches position AC3 through the normally open contact of K2, phase B power directly reaches position AC2, and phase C power reaches position AC1 through the normally open contact of K2. The motor obtains power according to this phase sequence, achieving forward rotation and driving the roller shutter door upward. Relay activated state: When the microcontroller's P1.0 and P1.1 pins output a high level, the OUT1 and OUT2 pins of the ULN2003 chip are at a low level, and the coils of relays K1 and K2 are energized, causing the contacts to close. At this time, phase A power reaches position AC1 through the normally open contact of K1, phase B power still directly reaches position AC2, and phase C power reaches position AC3 through the normally open contact of K2. The phase sequence of the motor changes, causing it to reverse and drive the roller shutter door to descend.
[0053] See Figure 4The phase detection unit 230 includes three zero-crossing detection lines, which are respectively connected to the A, B, and C live wires of the three-phase power supply. For each of the three phases A, B, and C, the zero-crossing detection line includes a live wire L, a neutral wire N, a rectifier bridge D1, a current-limiting resistor R4, an optocoupler IC1, and a pull-up resistor R5. The signal between L and N is an AC signal, which is converted into a full-wave signal by the D1 rectifier bridge. When the full-wave signal voltage is greater than the optocoupler conduction voltage, the optocoupler output terminal is turned on, and the Ua terminal is at a low level. When the full-wave signal voltage is less than the optocoupler conduction voltage, the optocoupler output terminal is turned off, and the Ua terminal is at a high level. The zero-crossing detection lines are used to perform zero-crossing pulse detection on the three-phase power supply A, B, and C respectively. The signal Ua enters the control module 200, and the control module 200 realizes phase detection of the three-phase power supply based on the signal Ua.
[0054] The rectifier bridge D1 can be a low-power rectifier bridge, such as the KBPC3510. The current-limiting resistor R4 can be selected with an appropriate resistance value based on the rated current of the optocoupler and the three-phase power supply voltage. Assuming the rated current of the optocoupler IC1 is 10mA and the effective value of the three-phase power supply voltage is 220V, considering the voltage change after rectification, a 20KΩ resistor with a power rating of 1W is selected for R4 to ensure that the current through the optocoupler is within a safe range. The optocoupler IC1 can be a common linear optocoupler, the PC817. The pull-up resistor R5 can be a 10KΩ pull-up resistor to ensure that the Ua terminal remains stable at a high level when the optocoupler is off.
[0055] Circuit Connections: For the zero-crossing detection circuit of each phase: the live wire L and the neutral wire N are connected to the AC input terminal of rectifier bridge D1. The positive DC output terminal of rectifier bridge D1 is connected to one end of current-limiting resistor R4, and the other end of current-limiting resistor R4 is connected to the anode of the input terminal of optocoupler IC1. The cathode of the input terminal of optocoupler IC1 is connected to the negative DC output terminal of rectifier bridge D1. The collector of the output terminal of optocoupler IC1 is connected to the power supply VCC (e.g., 3.3V) through pull-up resistor R5, and is also connected as the Ua terminal to the external interrupt input pin of control module 200. The emitter of the output terminal of optocoupler IC1 is grounded.
[0056] The implementation principle of the phase detection unit 230 is as follows: The AC signal between the live wire L and the neutral wire N of each phase (A, B, C phases) of the three-phase power supply is input into the rectifier bridge D1, which converts the AC signal into a full-wave signal. The voltage of the full-wave signal is always positive, but it still changes periodically with time. When the voltage of the full-wave signal is greater than the turn-on voltage of the optocoupler IC1 (typically 1.2V-1.5V), current flows through the input terminal of the optocoupler IC1, the output terminal of the optocoupler is turned on, and the Ua terminal is pulled low to near ground level, which is a low level. When the voltage of the full-wave signal is less than the turn-on voltage of the optocoupler IC1, there is no current at the input terminal of the optocoupler IC1, the output terminal of the optocoupler is turned off, and the Ua terminal is connected to VCC through the pull-up resistor R5, which is a high level. At the instant the AC signal crosses zero, the voltage of the full-wave signal will change from being greater than the turn-on voltage of the optocoupler to being less than the turn-on voltage of the optocoupler, or vice versa, causing the level of the Ua terminal to jump. The control module 200 captures the zero-crossing pulse signal by detecting the level change at the Ua terminal.
[0057] See Figure 3 2. The load current detection unit 240 includes AC Hall sensors H1, H2, and H3. The motor circuit connection lines pass through the AC Hall sensors, and the outputs of the AC Hall sensors are connected to the analog port of the control module 200 to enable the control module 200 to detect the load current. The AC Hall sensors can be LEM's LA series AC Hall sensors, such as the LA55-P.
[0058] Circuit Connections: The A, B, and C phase connection lines of the motor pass through the center holes of AC Hall sensors H1, H2, and H3, respectively. Each AC Hall sensor has two output pins: one for signal output and one for ground. The signal output pin of the AC Hall sensor is connected to the analog input port of control module 200 through an RC filter circuit (such as a 10KΩ resistor and a 0.1μF capacitor in series) to filter out high-frequency noise interference. The ground pin is directly connected to the ground (GND) of control module 200.
[0059] The operating principle of the load current detection unit 240 is as follows: The AC Hall sensor operates based on the Hall effect. When the magnetic field generated by the current in the motor circuit passes through the Hall sensor, the Hall sensor generates a voltage signal proportional to the current. This voltage signal is processed by the internal circuit and output from the signal output pin. The ADC of the control module 200 acquires the analog voltage signal output by the AC Hall sensor and converts it into a digital value. Based on the digital value obtained by the ADC conversion, combined with the sensitivity and calibration parameters of the Hall sensor, the microcontroller calculates the actual current value in the three-phase circuit of the motor.
[0060] The power supply 300 is located inside the housing 100 and is connected to the control module 200 to provide power to the control module 200. Specifically, the power supply 300 can be a switching power supply, such as Mean Well's LRS series. It has an input voltage of 220VAC, an output voltage of 24VDC, and a power rating of 100W, providing stable power to the control module 200. A filter capacitor and a voltage regulator circuit are added to the output of the switching power supply to reduce power ripple and voltage fluctuations, ensuring stable operation of the control module 200.
[0061] The backup power supply 400 is located inside the housing 100 and is connected to the control module 200. It is used to provide power to the control module 200 when the power supply 300 is abnormal.
[0062] Specifically, the backup power supply 400 can be a lead-acid battery, such as a 12V, 7Ah maintenance-free lead-acid battery. A dedicated battery charging management chip, such as TI's BQ series, is used to manage the backup battery's charging, ensuring battery safety and long lifespan. When the power supply 300 is normal, the charging management chip charges the backup battery; when the power supply 300 is abnormal, the backup battery provides power to the control module 200 via a DC-DC converter.
[0063] Example 2
[0064] See Figure 5 The control module 200 also includes a motor connection line monitoring unit 250, see [link to relevant documentation]. Figure 3 3. The motor connection line detection unit includes DIO1, AD1 and AD2. DIO1 is connected to the digital output port of the control module 200, and AD1 and AD2 are connected to the analog input port of the control module 200. When the motor is not working, the output voltage of DIO1 is output to AD1 and AD2 through the internal circuit of the motor. The control module 200 determines whether there is an open circuit in the motor connection line by monitoring the voltage of AD1 and AD2.
[0065] Specifically, DIO1 serves as a digital output port, providing a stable reference voltage, typically set to 5V or 3.3V, depending on the power supply and system design of the control module 200. Appropriate current-limiting resistors, such as 1KΩ-10KΩ resistors, should be added between the motor's internal wiring and AD1 and AD2 to protect the analog input ports of the control module 200 from overcurrent damage.
[0066] Circuit Connection: Connect DIO1 to the digital output port of control module 200, which outputs a known stable voltage signal. This signal is transmitted to AD1 and AD2 through the internal wiring of the motor. AD1 and AD2 are connected to the analog input ports of control module 200, respectively. Connecting different points in the internal wiring of the motor to AD1 and AD2 forms a simple voltage divider structure, facilitating the detection of voltage changes in the circuit.
[0067] The operating principle of the motor connection line monitoring unit 250 is as follows: When the motor is not working, DIO1 outputs a stable voltage. This voltage is transmitted to AD1 and AD2 through the internal circuitry of the motor. Since the internal circuitry of the motor is normally conductive, AD1 and AD2 will detect a stable voltage value related to the output voltage of DIO1. Based on the circuit design and the principle of resistor voltage division, the control module 200 can calculate the voltage range that AD1 and AD2 should have under normal conditions.
[0068] When an open circuit occurs in the motor connection line, current cannot flow normally through the open circuit point. This will cause significant changes in the voltage detected by AD1 and AD2. For example, if the open circuit point is on the line connecting AD1, the voltage detected by AD1 may be close to 0V; if the open circuit point is on the line connecting AD2, the voltage detected by AD2 will be abnormal. The control module 200 can determine whether there is an open circuit in the motor connection line by comparing the actual voltages detected by AD1 and AD2 with the normal voltage range.
[0069] Example 3
[0070] See Figure 6 The connection terminals on the housing 100 are also connected to the fire alarm controller 500 to receive fire alarm signals sent by the fire alarm controller 500, and to control the roller shutter door to rise and fall to a preset position when the fire alarm signal sent by the fire alarm controller 500 is received.
[0071] Specifically, the corresponding pins of the connection terminal are connected to the alarm signal output terminal (usually a dry contact output) and the common terminal of the fire alarm controller 500, respectively. Through this connection, when the fire alarm controller 500 detects a fire and issues an alarm signal, the signal is transmitted to the connection terminal and then to the control module 200.
[0072] The implementation principle of a roller shutter door controller according to an embodiment of this application is as follows: A GPIO pin of the control module 200 is connected to the output of the interface circuit for detecting fire alarm signals. In the software, this GPIO pin is configured as an input mode, and an interrupt function is used to respond to changes in the fire alarm signal in real time. When a valid fire alarm signal is detected (such as dry contact closure), an interrupt service routine is triggered. The preset position information of the roller shutter door, such as half-closed position (for fire separation) and full-closed position (for complete closure), is pre-stored in the memory of the control module 200. When a fire alarm signal is received, the control module 200 determines which position the roller shutter door should be moved to according to preset logic. For example, if it is a level one fire alarm, the roller shutter door is controlled to descend to the half-closed position; if it is a level two fire alarm or the fire continues to develop, the roller shutter door is controlled to descend to the full-closed position. According to the determined preset position, the control module 200 controls the motor to rotate forward and backward through the commutation control unit 220 (such as the circuit composed of relays K1 and K2 mentioned above), so that the roller shutter door is raised or lowered to the specified position. During the movement of the roller shutter door, the roller shutter door position detection unit 210 monitors the position of the roller shutter door in real time, and stops the motor when it reaches the preset position.
[0073] Example 4
[0074] See Figure 7 The control module 200 also includes a status display unit 260, which includes a buzzer 261 and a status indicator light 262. When the control module 200 detects an abnormality in the three-phase power supply, an abnormality in the line connected to the motor, or an abnormality in the motor operation, the buzzer 261 emits a sound and the status indicator light 262 lights up.
[0075] Specifically, the buzzer 261 can be an active buzzer 261, such as an electromagnetic active buzzer 261. The positive terminal of the buzzer 261 is connected to a GPIO pin of the control module 200 through a current-limiting resistor (such as 1KΩ), and the negative terminal is grounded. When the GPIO pin outputs a high level, the buzzer 261 is powered on and sounds; when it outputs a low level, the buzzer 261 stops sounding.
[0076] The status indicator 262 can be a high-brightness light-emitting diode (LED), and its color can be distinguished according to different abnormal states, such as red for serious faults and yellow for general abnormalities. The anode of each status indicator 262 is connected to a different GPIO pin of the control module 200 through a current-limiting resistor (e.g., 330Ω), and the cathode is grounded. When the corresponding GPIO pin outputs a high level, the indicator light is on; when it outputs a low level, the indicator light is off.
[0077] The control signal for the status display unit 260 is generated by the control module 200 based on the detection results of the roller shutter positioning detection unit 210, the commutation control unit 220, the phase detection unit 230, and the load current detection unit 240. For example, when the phase detection unit 230 detects a phase sequence error or voltage abnormality, it feeds back the abnormality signal to the control module 200, and the control module 200 accordingly controls the buzzer 261 and the status indicator light 262 to operate.
[0078] The implementation principle of a roller shutter door controller in this application embodiment is as follows: when the control module 200 detects any abnormality in the detection results of the roller shutter positioning detection unit 210, the phase switching control unit 220, the phase detection unit 230, and the load current detection unit 240, it immediately controls the buzzer 261 and the corresponding status indicator light 262 to work.
[0079] Example 5
[0080] See Figure 8 The roller shutter door controller also includes a manual control module 600, which includes a button unit 610, a status indicator unit 620, a sound unit 630, and a communication unit 640. The manual control module 600 is connected to the control module 200 and is used to process button operations.
[0081] The button unit 610 can use mechanical tactile buttons. The button layout includes function buttons such as "Up," "Down," "Stop," and "Emergency Stop" to achieve basic manual control of the roller shutter door. One end of each button is grounded, and the other end is connected to the GPIO pin of the control module 200 through a pull-up resistor (e.g., 10KΩ). When a button is pressed, the corresponding GPIO pin goes low, and the control module 200 recognizes the button operation accordingly.
[0082] The status indicator unit 620 can use different colored light-emitting diodes (LEDs) to indicate the status of the roller shutter door, such as green for normal operation, yellow for pause, and red for fault. The status indicator unit 620 is connected to the corresponding GPIO pin of the control module 200 through a current-limiting resistor (e.g., 330Ω), with the cathode grounded. The control module 200 controls the corresponding indicator light to turn on and off according to the operating status of the roller shutter door.
[0083] The sound unit 630 can be a piezoelectric buzzer 261, with one end connected to the PWM output pin of the control module 200 and the other end grounded. The sound effect of the buzzer 261 can be changed by controlling the PWM duty cycle, and it can be used for scenarios such as button operation feedback and fault alarm.
[0084] Furthermore, the manual control module 600 has a built-in MCU, which facilitates the handling of button presses, status prompts, and audible alarms, and enables communication with the roller shutter door controller.
[0085] The communication unit 640 can use an RS485 communication chip, such as the MAX485, which features long transmission distance (up to kilometers) and strong anti-interference capability, enabling stable communication with the control module 200. Connect the RO pin of the MAX485 chip to the receive pin of the control module 200, the DI pin to the transmit pin of the control module 200, and the RE and DE pins to control the transmit / receive status via the GPIO pins of the control module 200. Connect the A and B pins to an external RS485 bus to achieve data interaction with other devices.
[0086] The implementation principle of a roller shutter door controller according to an embodiment of this application is as follows: the manual control module 600 and the control module 200 are connected via pins and a communication interface. The button operation signals of the button unit 610 are directly transmitted to the control module 200 via pins, and the control module 200 controls the roller shutter door based on these signals. The communication unit 640 provides a channel for the control module 200 to interact with external devices. The control module 200 can send the roller shutter door's status information (such as position, operating status, etc.) to external devices through the communication unit 640, and simultaneously receive control commands from external devices, thereby realizing remote control and monitoring of the roller shutter door.
[0087] 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. A roller shutter door controller, characterized in that, include: The housing (100) is equipped with output connection terminals, which are respectively connected to a three-phase power supply, a motor circuit and a roller shutter door position feedback circuit; The control module (200) is located inside the housing (100). The control module (200) includes a roller shutter position detection unit (210), a phase commutation control unit (220), a phase detection unit (230), and a load current detection unit (240). The roller shutter position detection unit (210) is connected to the roller shutter door position feedback line and is used to detect the position of the roller shutter door. The phase commutation control unit (220) is connected to the three-phase power supply and is used to control the motor to rotate forward / reverse. The phase detection unit (230) is connected to the three-phase power supply and is used to detect the phase sequence of the three-phase power supply. The load current detection unit (240) is connected to the motor line and is used to detect the motor current. A power supply (300) is located inside the housing (100) and connected to the control module (200) to provide power to the control module (200); A backup power supply (400) is located inside the housing (100) and connected to the control module (200) to provide power to the control module (200) when the power supply (300) is abnormal.
2. The roller shutter door controller according to claim 1, characterized in that, The connection terminals on the housing (100) are also connected to the fire alarm controller (500) for receiving fire alarm signals sent by the fire alarm controller (500) and controlling the roller shutter door to rise and fall to a preset position when the fire alarm signal sent by the fire alarm controller (500) is received.
3. The roller shutter door controller according to claim 1, characterized in that, The roller shutter position detection unit (210) includes multiple detection lines, which are used to detect the switch status of the IO1 port. When the roller shutter door is in operation, the limit switch with roller shutter position is turned on, and IO1 is at a low level; the limit switch without roller shutter position is turned off, and the voltage of IO1 is at a high level. The control module (200) determines the position of the roller shutter door by detecting the level status of the IO ports connected to the multiple limit switches.
4. The roller shutter door controller according to claim 1, characterized in that, The phase-switching control unit (220) includes relays K1 and K2, which control the connection sequence of the three-phase power supply (A, B, and C) to the motor. When relays K1 and K2 are not activated, the A-phase power supply passes through K2 to reach position AC3, the B-phase power supply passes through K2 to reach position AC2, and the C-phase power supply passes through K2 to reach position AC1. When relays K1 and K2 are activated, the A-phase power supply passes through K1 to reach position AC1, the B-phase power supply passes through K1 to reach position AC2, and the C-phase power supply passes through K2 to reach position AC3, thereby realizing the forward / reverse rotation of the motor and controlling the lifting and lowering of the roller shutter door.
5. The roller shutter door controller according to claim 1 or 4, characterized in that, The phase detection unit (230) includes three zero-crossing detection lines, which are respectively connected to the A, B, and C live wires of the three-phase power supply. For each of the three phases A, B, and C, the zero-crossing detection line includes a live wire L, a neutral wire N, a rectifier bridge D1, a current-limiting resistor R4, an optocoupler IC1, and a pull-up resistor R5. The signal between L and N is an AC signal, which is converted into a full-wave signal by the D1 rectifier bridge. When the full-wave signal voltage is greater than the optocoupler conduction voltage, the optocoupler output terminal is turned on, and the Ua terminal is at a low level. When the full-wave signal voltage is less than the optocoupler conduction voltage, the optocoupler output terminal is turned off, and the Ua terminal is at a high level. The zero-crossing detection lines are used to perform zero-crossing pulse detection on the three-phase power supply A, B, and C respectively. The signal Ua enters the control module (200), and the control module (200) realizes the phase detection of the three-phase power supply based on the signal Ua.
6. The roller shutter door controller according to claim 1, characterized in that, The load current detection unit (240) includes AC Hall sensors H1, H2, and H3. The connecting lines of the motor circuit pass through the AC Hall sensors respectively. The output of the AC Hall sensors is connected to the analog port of the control module (200) to realize the detection of load current by the control module (200).
7. The roller shutter door controller according to claim 1, characterized in that, The control module (200) also includes a motor connection line monitoring unit (250), which includes DIO1, AD1 and AD2. DIO1 is connected to the switch output port of the control module (200), and AD1 and AD2 are connected to the analog input port of the control module (200). When the motor is not working, the output voltage of DIO1 is output to AD1 and AD2 through the internal circuit of the motor. The control module (200) determines whether there is an open circuit in the motor connection line by monitoring the voltage of AD1 and AD2.
8. The roller shutter door controller according to claim 1, characterized in that, The control module (200) also includes a status display unit (260), which includes a buzzer (261) and a status indicator (262). When the control module (200) detects an abnormality in the three-phase power supply, an abnormality in the line connected to the motor, or an abnormality in the motor operation, the buzzer (261) emits a sound and the status indicator (262) lights up.
9. The roller shutter door controller according to claim 1, characterized in that, The roller shutter door controller also includes a manual control module (600), which includes a button unit (610), a status indicator unit (620), a sound unit (630), and a communication unit (640). The manual control module (600) is connected to the control module (200) and is used to process button operations and status prompts.