Two-way transmission industrial wireless remote controller with one-to-two function

Abstract

The utility model relates to a two-way transmission industrial wireless remote controller with a one-to-two function. The two-way transmission industrial wireless remote controller comprises a transmitter part (10), two receiver parts (30), a transmitting antenna (20), a receiving antenna (40) and a crane part (50), the control part (11), the encoder (13) and the first bidirectional high-frequency module (14) of the transmitter (10) are electrically connected with the CPU (16) through the mainboard (12), and the first bidirectional high-frequency module (14) is connected with the directional antenna (20) through a coaxial cable. A second bidirectional high-frequency module (31) of the receiver (30) is connected with double decoders (321 / 322) and double CPUs (331 / 332), and the output end of the second bidirectional high-frequency module (31) controls the crane (50) through an emergency stop relay (34). The transmitter and the receiver realize real-time signal interaction through a bidirectional high-frequency module, and the hardware level is triggered to be automatically closed in case of abnormality; and the receiver adopts a double-decoder and double-CPU redundancy design, so that the power supply of the crane can be cut off when any fault occurs.

Description

Technical Field

[0001] This utility model relates to the field of wireless communication, and in particular to an industrial wireless remote control with a one-to-two function for bidirectional transmission. Background Technology

[0002] Currently, industrial wireless remote controls are widely used in the control of equipment such as cranes, especially in one-to-two lifting operations, where a single transmitter controls two receivers to achieve synchronous or independent operation. In existing technologies, such remote controls mostly employ a unidirectional signal transmission mode, meaning the transmitter only sends operating commands to the receiver, while the receiver cannot provide real-time status information back to the transmitter. This type of unidirectional transmission system typically consists of a transmitter, a receiver, and a unidirectional high-frequency module. Its function relies on the transmitter continuously sending commands, with the receiver passively executing them and triggering local protection mechanisms (such as emergency stop relays).

[0003] However, unidirectional transmission poses significant safety risks in one-to-two scenarios. For example, when one receiver stops working due to a signal anomaly triggering a protection mechanism, the transmitter is unaware of this status and continues to send operating commands to the other receiver, causing the two devices to operate out of sync. In lifting operations, such problems could lead to the tilting of heavy objects, equipment damage, or even personal injury. Furthermore, existing receivers typically use a single decoder and control unit; if a malfunction occurs during decoding or processing, the emergency stop function may not be reliably triggered, further exacerbating safety risks. Utility Model Content

[0004] To address the aforementioned issues, this utility model proposes a one-to-two industrial wireless remote controller with bidirectional transmission. By configuring bidirectional high-frequency modules for the transmitter and receiver, real-time signal interaction and status monitoring are achieved, ensuring that the transmitter and receiver can synchronously trigger the automatic shutdown function when either device malfunctions. Simultaneously, the receiver employs a redundant design with dual decoders and dual control units, enhancing fault detection reliability through hardware connections and preventing protection mechanism failure due to single-point failure, thereby significantly improving system security. To achieve the above objectives, this application provides a one-to-two bidirectional industrial wireless remote controller, comprising: a transmitter section (10), a first receiver section, a second receiver section, a transmitting antenna (20), a receiving antenna (40), and a crane section (50);

[0005] The transmitter section (10) includes a control section (11), a transmitter motherboard (12), an encoder (13), a first bidirectional high-frequency module (14), a decoder (15), a CPU (16), and a transmitting antenna (20); the control section (11), the encoder (13), and the CPU (16) are electrically connected to the transmitter motherboard (12); the input end of the first bidirectional high-frequency module (14) is connected to the encoder (13), the output end is connected to the transmitting antenna (20), and the feedback end of the first bidirectional high-frequency module (14) is connected to the decoder (15); the output end of the decoder (15) is connected to the CPU (16), and the output end of the CPU (16) is connected to the transmitter motherboard (12);

[0006] Both the first receiver section and the second receiver section include a second bidirectional high-frequency module (31), a first decoder (321), a second decoder (322), a first CPU (331), a second CPU (332), an emergency stop relay (34), and a receiving antenna (40); the input terminal of the second bidirectional high-frequency module (31) is connected to the receiving antenna (40), and the output terminal is connected to the first decoder (321) and the second decoder (322) respectively; the output terminals of the first decoder (321) and the second decoder (322) are connected to the first CPU (331) and the second CPU (332) respectively; the output terminals of the first CPU (331) and the second CPU (332) are connected to the emergency stop relay (34);

[0007] The crane section (50) is connected to the output terminal of the emergency stop relay (34).

[0008] Optionally, the transmitter motherboard (12) and the first bidirectional high-frequency module (14) are connected via a signal bus.

[0009] Optionally, the second bidirectional high-frequency module (31) in the first receiver section and the second receiver section communicates with the transmitting antenna (20) through an independent channel.

[0010] Optionally, the emergency stop relay (34) is a two-contact relay, and its input terminal is connected to the output terminal of the first CPU (331) and the second CPU (332) respectively.

[0011] Optionally, the transmitting antenna (20) and the receiving antenna (40) are narrowband directional antennas.

[0012] Optionally, the control unit (11) includes physical buttons and a joystick, which are fixed to the surface of the transmitter housing and electrically connected to the transmitter motherboard (12).

[0013] The technical solutions provided in this application embodiment may include the following beneficial effects:

[0014] The industrial wireless remote controller provided in this application enables bidirectional signal transmission and real-time status interaction by equipping both the transmitter and receiver with bidirectional high-frequency modules. When either receiver malfunctions, the transmitter can immediately receive the fault feedback signal and simultaneously trigger the automatic shutdown function, forcibly stopping all operation command output. This avoids the problem of asynchronous action between the two machines due to the malfunction of a single device, significantly reducing the safety risks in lifting operations.

[0015] The receiver section adopts an independent hardware configuration of dual decoders (321 / 322) and dual CPUs (331 / 332), which interact with the emergency stop relay (34) through parallel connection. When either decoder or CPU detects an abnormality, it can independently trigger the emergency stop relay to disconnect, realizing hardware-level redundancy protection, completely avoiding the safety mechanism failure problem caused by single point failure, and ensuring that the system can still be reliably shut down under abnormal operating conditions.

[0016] The transmitting antenna (20) and receiving antenna (40) adopt a narrow-band directional design, which limits the signal propagation range through physical structure and reduces the impact of environmental interference on wireless communication. Combined with the real-time feedback mechanism of the bidirectional high-frequency module, the stability of command transmission and status monitoring is further guaranteed, which is especially suitable for complex electromagnetic interference working environments in industrial scenarios.

[0017] The transmitter motherboard (12) and CPU (16) are directly electrically connected to receive feedback signals from the decoder (15). Without relying on software judgment, the system can quickly decide whether to activate the automatic shutdown function based on changes in hardware signal levels. This hardware-level linkage mechanism significantly shortens the response time to abnormal states, ensuring that the system cuts off the output within milliseconds and minimizing safety risks. Attached Figure Description

[0018] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0019] Figure 1 This is a schematic block diagram of an industrial wireless remote controller with bidirectional transmission and a one-to-two function, provided by this utility model. Detailed Implementation

[0020] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0021] Please see Figure 1 The industrial wireless remote controller of this utility model includes a transmitter part 10, a first receiver part 30, a second receiver part 30, a transmitting antenna 20, a receiving antenna 40, and a crane part 50. The specific structure, connection relationship, and positional layout of each module are described in detail below with reference to each claim, and operational examples are provided:

[0022] In this embodiment, the transmitter housing is made of engineering plastic, and the front panel houses the control unit 11, including physical buttons and a joystick. The buttons are covered with a silicone protective layer and contain spring-loaded switches, connected to the transmitter motherboard 12 via a 24-pin flexible ribbon cable (FPC). The joystick has a built-in Hall sensor that transmits analog signals to the motherboard 12 via a ribbon cable. The motherboard 12 is a multi-layer PCB circuit board, installed in the center of the housing and secured with bolts to enhance shock resistance. An encoder 13, using an STM32 series chip, is soldered to the left side of the motherboard. After receiving the analog signals from the control unit 11, it converts them into digital commands and sends them to the first bidirectional high-frequency module 14 on the right side via a serial interface.

[0023] The first bidirectional high-frequency module 14 is encapsulated in a metal shield and located on the right side of the motherboard. It communicates with the motherboard 12 via an SPI bus, including three signal lines: SCLK, MOSI, and MISO, with a transmission rate of 10Mbps. The module's transmitting end is connected to the transmitting antenna 20 on the top of the casing via a coaxial cable, and the receiving end is connected to the adjacent decoder 15 via a shielded wire. The decoder 15 uses an ADF7021 chip, which decodes the feedback signals captured by the receiving antenna 20, such as receiver status codes, into digital signals and transmits them to the CPU 16 on the top of the motherboard via parallel data lines. The CPU 16 is an ARM Cortex-M4 processor integrated on the motherboard 12, which uses a hardware level comparison circuit to determine the signal status in real time. If an anomaly is detected, such as a receiver fault code, the CPU 16 immediately sends a low-level signal to the motherboard 12 via a GPIO pin, triggering an automatic shutdown function and cutting off all instruction output.

[0024] The transmitting antenna 20 is a narrow-band directional antenna, fixed to the top of the housing. It adopts a microstrip patch array design with a main lobe width of 60° and a side lobe suppression ratio of >20dB. The radiation range is limited by a metal waveguide, which effectively reduces multipath interference in the industrial environment.

[0025] In this embodiment, the first receiver 30 and the second receiver 30 have identical structures. A second bidirectional high-frequency module 31 is installed at the front end inside the housing and connected to the receiving antenna 40 on top via a coaxial cable. For example, module 31 operates at 2.4 GHz, supports full-duplex communication, and its transmitter and receiver are physically isolated, connected to the first decoder 321 and the second decoder 322 respectively via shielded cables. The two decoders 321 / 322 are soldered side-by-side on the left side of the PCB board, both using the ADF7021 chip, and independently decode signals from the second bidirectional high-frequency module 31. The decoded instructions are transmitted via a parallel data bus to the first CPU 331 and the second CPU 332 on the right side, respectively.

[0026] The first CPU 331 and the second CPU 332 are designed with dual-core redundancy and are integrated on independently powered circuit boards. They are connected to the emergency stop relay 34 via optocouplers. The emergency stop relay 34 is a dual-contact magnetic latching relay, mounted at the bottom of the receiver, with a contact spacing of 5.2mm and ceramic insulating material filling the contact gaps. The relay input is connected in series with the motor control circuit of the crane 50 via a copper busbar and remains closed under normal conditions. When either CPU detects an abnormality, such as signal over-limit or communication interruption, it immediately outputs a low-level signal, driving the electromagnetic coil to physically separate the contacts and forcibly cut off the crane's power supply.

[0027] The receiving antenna 40 is the same as the transmitting antenna 20, and is a narrow-band directional design. It is installed on the top of the receiver housing and connected to the second bidirectional high-frequency module 31 via a coaxial cable to ensure signal reception sensitivity.

[0028] In this embodiment, the motor drive module of the crane 50 is connected to the output terminal of the emergency stop relay 34 via a cable. The relay contacts directly control the on / off state of the power circuit. When any receiver 30 triggers an emergency stop, the contacts mechanically separate, and the crane immediately stops operating.

[0029] The structure of this application will be further described below with examples of inter-module communication and operation.

[0030] Normal operating procedure:

[0031] The operator pushes the joystick to send a "leftward" command. The Hall sensor in the control unit 11 generates an analog signal, which is converted into the digital code "0xA1" by the encoder 13. The first bidirectional high-frequency module 14 transmits the signal simultaneously to two receivers 30 via the transmitting antenna 20 in the 2.4GHz band. After the second bidirectional high-frequency module 31 of the receiver 30 receives the signal, the first decoder 321 and the second decoder 322 independently parse the command, and the dual CPUs 331 / 332 respectively verify the validity of the data. If the verification passes, the CPU outputs a high level, the emergency stop relay 34 remains closed, and the crane performs the leftward movement.

[0032] Exception handling process:

[0033] If the first receiver 30 fails to decode due to signal interference, the first CPU 331 detects an instruction overrun and immediately outputs a low level to trigger the emergency stop relay 34 to disconnect. Simultaneously, the second bidirectional high-frequency module 31 of the receiver 30 sends the fault code "0xE1" to the transmitter 10. After the decoder 15 of the transmitter 10 parses the code, the CPU 16 notifies the mainboard 12 to activate the automatic shutdown function via a level transition, cutting off the instruction output. The second receiver 30 synchronously receives the shutdown signal, and its CPU 332 triggers the emergency stop relay 34 to disconnect, causing both cranes to stop synchronously and preventing the load from tilting during lifting operations.

[0034] Optionally, the SPI bus between the transmitter motherboard 12 and the first bidirectional high-frequency module 14 uses shielded twisted-pair cable, with the signal line length not exceeding 10cm, to reduce transmission delay. The bus clock frequency is set to 10MHz to ensure real-time communication.

[0035] Optionally, the first receiver 30 uses the 2.401 GHz band and the second receiver 30 uses the 2.423 GHz band, switching sub-channels every 100 ms using frequency hopping technology to avoid co-channel interference.

[0036] Optionally, the two contacts of the emergency stop relay 34 are driven by independent electromagnetic coils with a coil resistance of 120Ω and a driving voltage of 12V. The contact separation time is <10ms, ensuring rapid power cut-off.

[0037] Optionally, the antenna gain is 8dBi, impedance is 50Ω, and operating bandwidth is 20MHz. The matching is calibrated using a vector network analyzer to ensure a standing wave ratio (VSWR) of <1.5.

[0038] Optionally, silicone anti-vibration pads are added to the connectors of the buttons and joysticks, and the bending radius of the cables is greater than 5mm to prevent breakage caused by repeated bending. The joystick base is fixed with screws to prevent loosening and displacement.

[0039] Furthermore, in an optional embodiment, the transmitter 10 incorporates a built-in lithium-ion battery pack, which is converted to 3.3V and 5V voltages via a DC-DC module on the motherboard 12, supplying power to the CPU and decoder respectively. The receiver 30 uses a 24V industrial DC power supply, which powers the dual CPUs via an isolated power module.

[0040] Rubber sealing rings are added to the outer casing interfaces, achieving an IP65 protection rating, suitable for dusty and humid environments. The motherboard 12 is coated with conformal coating to prevent corrosion and effectively enhance environmental adaptability.

[0041] Through the specific implementation of the above hardware structure and connection relationship, this utility model realizes two-way real-time monitoring, redundant safety protection and anti-interference communication, which significantly improves the reliability and security of industrial remote control system.

[0042] Other embodiments of this application will readily conceive of by those skilled in the art upon consideration of the specification and practice of the technical solutions disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. The specification and embodiments are to be considered exemplary only, and the true scope and spirit of this application are indicated by the following claims.

[0043] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. An industrial wireless remote controller of one-to-two function bidirectional transmission, characterized in that, The application relates to a crane control system. The transmitter part (10) comprises a control part (11), a transmitter mainboard (12), an encoder (13), a first bidirectional high-frequency module (14), a decoder (15), a CPU (16) and a transmitting antenna (20); the control part (11), the encoder (13) and the CPU (16) are electrically connected with the transmitter mainboard (12) respectively; the input end of the first bidirectional high-frequency module (14) is connected with the encoder (13), the output end is connected with the transmitting antenna (20), and the feedback end of the first bidirectional high-frequency module (14) is connected with the decoder (15); the output end of the decoder (15) is connected with the CPU (16), and the output end of the CPU (16) is connected with the transmitter mainboard (12). The first receiver part and the second receiver part both comprise a second bidirectional high-frequency module (31), a first decoder (321), a second decoder (322), a first CPU (331), a second CPU (332), an emergency stop relay (34) and a receiving antenna (40); the input end of the second bidirectional high-frequency module (31) is connected with the receiving antenna (40), and the output end is connected with the first decoder (321) and the second decoder (322) respectively; the output ends of the first decoder (321) and the second decoder (322) are connected with the first CPU (331) and the second CPU (332) respectively; the output ends of the first CPU (331) and the second CPU (332) are connected with the emergency stop relay (34). The crane part (50) is connected with the output end of the emergency stop relay (34). The transmitter mainboard (12) is connected with the first bidirectional high-frequency module (14) through a signal bus.

2. The industrial wireless remote controller of claim 1, wherein, The second bidirectional high-frequency module (31) in the first receiver part and the second receiver part communicates with the transmitting antenna (20) through an independent channel.

3. The industrial wireless remote controller of claim 1, wherein, The emergency stop relay (34) is a double-contact relay, and the input ends are connected with the output ends of the first CPU (331) and the second CPU (332) respectively.

4. The industrial wireless remote controller of claim 1, wherein, The transmitting antenna (20) and the receiving antenna (40) are narrow-frequency directional antennas.

5. The industrial wireless remote controller of claim 1, wherein, The control part (11) comprises physical buttons and a joystick, is fixed on the surface of a transmitter shell and is electrically connected with the transmitter mainboard (12).

6. The industrial wireless remote controller of claim 1, wherein, ​

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