Industrial data communication system

Abstract

The utility model discloses an industrial data communication system, which comprises a data acquisition device at a field end and a data transfer device at a background end, wherein the data transfer device is connected with the data acquisition device; the data acquisition device comprises a main control module, a first signal isolation module and a first wireless communication module which are connected in sequence; wherein the isolation side module of the first signal isolation module is connected with the first wireless communication module; the data transfer device comprises a second signal isolation module and a second wireless communication module; wherein the isolation side module of the second signal isolation module is connected with the second wireless communication module; the first wireless communication module is connected with the second wireless communication module through a wireless communication line. Therefore, reliable wireless communication between the data acquisition device at the field end of the well site and the data transfer device at the background end is ensured through a dual-signal isolation design.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of well site communication system, especially to an industrial data communication system. BACKGROUND

[0002] In the process of downhole exploration and operation of oil, natural gas and other resources, the monitoring and data acquisition of downhole operation are crucial links, and how to efficiently and reliably transmit the downhole information to the ground is an important challenge faced by downhole operation.

[0003] In the related art, cable communication is usually used to realize data transmission between the data acquisition device of the field end and the data transfer device of the background end in the well site scene. However, in the complex well site environment, the reliability of data transmission needs to be improved. SUMMARY

[0004] The utility model aims at at least in a certain extent solves one of the technical problems in the related art. For this purpose, the utility model provides an industrial data communication system, which ensures stable, reliable and efficient wireless communication between the data acquisition device of the field end and the data transfer device of the background end, realizes accurate data transmission, and provides strong support for the safety and efficiency of downhole operation.

[0005] To achieve the above purpose, the utility model discloses a first aspect of embodiment of industrial data communication system, applied to well site, the industrial data communication system includes the data acquisition device of field end, and the data transfer device of background end connected with the data acquisition device;The data acquisition device includes the main control module, the first signal isolation module and the first wireless communication module connected in turn;Among them, the main control module is connected with the non-isolated side module of the first signal isolation module;The isolated side module of the first signal isolation module is connected with the first wireless communication module;The data transfer device includes the second signal isolation module and the second wireless communication module;Among them, the non-isolated side module of the second signal isolation module is used to be connected with host end;The isolated side module of the second signal isolation module is connected with the second wireless communication module;The first wireless communication module and the second wireless communication module are connected through wireless communication line.

[0006] According to one embodiment of the utility model, the host end and the non-isolated side module of the second signal isolation module are connected through the communication protocol conversion module.

[0007] According to one embodiment of the utility model, the communication protocol conversion module specifically adopts USB to serial chip.

[0008] According to one embodiment of the utility model, the working voltage of the communication protocol conversion module includes 3.3 volts and 5 volts.

[0009] According to one embodiment of the present invention, the data acquisition device further includes a first power isolation module, the power output terminal of the first power isolation module being connected to the power input terminal of the first wireless communication module; the data relay device further includes a second power isolation module, the power output terminal of the second power isolation module being connected to the power input terminal of the second wireless communication module.

[0010] According to one embodiment of the present invention, the maximum output power of both the first power isolation module and the second power isolation module is 1 watt.

[0011] According to one embodiment of the present invention, the data acquisition device further includes a first voltage regulator module, wherein the power output terminal of the first power isolation module is also connected to the power input terminal of the first voltage regulator module, and the power output terminal of the first voltage regulator module is connected to the power input terminal of the isolation side module of the first signal isolation module; the data relay device further includes a second voltage regulator module, wherein the power output terminal of the second power isolation module is also connected to the power input terminal of the second voltage regulator module, and the power output terminal of the second voltage regulator module is connected to the power input terminal of the isolation side module of the second signal isolation module.

[0012] According to one embodiment of the present invention, the output voltage of both the first voltage regulator module and the second voltage regulator module is 3.3 volts.

[0013] According to one embodiment of the present invention, the maximum data rate of both the first signal isolation module and the second signal isolation module is 2 megabits per second.

[0014] According to one embodiment of the present invention, the maximum serial port baud rate of the first wireless communication module and the second wireless communication module is 115200 bits / second, and the air rate sets of the first wireless communication module and the second wireless communication module both include 250 kilobits / second, 1 megabit / second, and 2 megabit / second.

[0015] According to the various embodiments provided by this utility model, the dual signal isolation design can improve the electrical safety of the system, reduce the impact of noise and interference on the signal transmission path, enhance the anti-interference capability and reliability of wireless communication, thereby helping to improve the quality of data transmission, ensure reliable wireless communication between the data acquisition device at the field end and the data relay device at the back end in the well site scenario, ensure that the system can still operate stably under harsh working conditions at the well site, and improve the robustness and adaptability of the system.

[0016] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0017] Figure 1 This is a structural block diagram of an industrial data communication system provided according to an embodiment of the present utility model.

[0018] Figure 2 This is a schematic diagram showing the connection between the host terminal and the second signal isolation module according to an embodiment of the present invention.

[0019] Figure 3 This is a structural block diagram of another industrial data communication system provided according to an embodiment of the present utility model.

[0020] Figure 4 This is a structural block diagram of another industrial data communication system provided according to an embodiment of the present utility model.

[0021] Figure 5a This is a structural block diagram of a long-distance wireless communication system with isolation function provided according to an embodiment of the present utility model.

[0022] Figure 5b This is a schematic diagram of a wireless communication circuit for a hub box according to an embodiment of the present invention.

[0023] Figure 5c This is a schematic diagram of a ground box wireless communication circuit according to an embodiment of the present invention.

[0024] Figure 5d This is a circuit diagram of a power isolation module provided according to an embodiment of the present invention.

[0025] Figure 5e This is a circuit diagram of a voltage regulator module provided according to an embodiment of the present invention.

[0026] In the diagram: 100: Industrial data communication system; 110: Data acquisition device; 120: Data relay device; 112: Main control module; 114: First signal isolation module; 116: First wireless communication module; 122: Second signal isolation module; 124: Second wireless communication module; 200: Host terminal; 210: Communication protocol conversion module; 310: First power isolation module; 320: Second power isolation module; 410: First voltage regulator module; 420: Second voltage regulator module. Detailed Implementation

[0027] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0028] In downhole exploration and operations for resources such as oil and natural gas, downhole monitoring and data acquisition are crucial. Various data collected in real-time downhole by instruments need to be accurately and stably transmitted to the surface for processing and analysis to achieve real-time monitoring and precise control of downhole operations. Due to the complex and variable conditions downhole, efficiently and reliably transmitting downhole information to the surface is a significant challenge for downhole operations.

[0029] When the instrument is operating downhole, signals are transmitted to the surface in a specific form through the special medium of drilling mud. The mud sensor, connected to the junction box, collects the mud signals in real time. After collection, the data is sent to the ground box located in the instrument room. The ground box then uploads the data to the PC for subsequent data processing.

[0030] Because the mud sensor and junction box are located near the derrick, while the ground box is placed inside the instrument room, the two boxes are quite far apart, exceeding 30 meters. In related technologies, to ensure the stability and accuracy of data transmission, the RS485 communication protocol is typically used to connect the junction box and the ground box via cable. This communication method can provide reliable data transmission over a certain distance.

[0031] However, some well sites prohibit the presence of long cables due to strict safety considerations. This is because long cables can pose numerous safety hazards in the well site environment. For example, they are easily damaged by the complex working conditions downhole, causing electrical faults such as short circuits, and may even become one of the causes of accidents such as fires and explosions at the well site. At the same time, the laying and maintenance of long cables are also more complicated, and may cause inconvenience to the operation of personnel and the layout of equipment in the limited space of the well site.

[0032] As downhole operations increasingly demand higher levels of safety and flexibility, traditional wired communication methods are becoming increasingly inadequate in well sites where long cables are strictly limited. There is an urgent need for a solution to replace conventional cable communication. Advances in wireless communication technology, particularly short-range wireless communication for complex industrial environments, have provided new solutions. Wireless communication solutions can effectively avoid the limitations of traditional wired communication, such as reducing wiring workload, lowering construction risks, and improving system flexibility. Especially in well site environments requiring high safety standards, using wireless communication instead of conventional cables not only eliminates potential hazards caused by wires but also adapts to more diverse site layout requirements.

[0033] Considering the unique characteristics of downhole operating environments, such as potential electromagnetic interference, complex terrain, and spatial layout, it is necessary to propose an industrial data communication system to ensure the stability, reliability, and efficiency of wireless communication between the field junction box and the ground box at the back end, thereby achieving accurate data transmission and providing strong support for the safe and efficient operation of downhole operations. The industrial data communication system provided in this specification is applied to well site scenarios. The junction box is defined as the field-end data acquisition device, and the ground box is defined as the back-end data relay device. This industrial data communication system mainly consists of a data acquisition device and a data relay device, achieving data interaction through wireless communication lines to replace the cable communication solutions in related technologies. Specifically, the data acquisition device includes a main control module, a first signal isolation module, and a first wireless communication module. The non-isolated side module of the first signal isolation module is connected to the main control module, and the isolated side module is connected to the first wireless communication module to achieve signal isolation. This protects the first wireless communication module from electromagnetic coupling interference that may exist on the side where the main control module is located, ensuring the stability and reliability of wireless data transmission. The data relay device includes a second signal isolation module and a second wireless communication module. The non-isolated side module of the second signal isolation module is connected to the host, and the isolated side module is connected to the second wireless communication module to achieve signal isolation. The first wireless communication module and the second wireless communication module are connected via a wireless communication line to enable communication between the data acquisition device and the data relay device via wireless communication.

[0034] Therefore, by adopting a dual signal isolation design, the electrical safety of the system can be improved, the impact of noise and interference on the signal transmission path can be reduced, and the anti-interference capability of wireless communication can be enhanced. This helps to improve the quality of data transmission, realize reliable wireless communication between the data acquisition device at the field end and the data relay device at the back end in the well site scenario, ensure that the system can still operate stably under harsh working conditions at the well site, and improve the robustness and adaptability of the system.

[0035] This specification provides an industrial data communication system applied in well sites. (Reference) Figure 1 As shown, the industrial data communication system 100 includes a field-end data acquisition device 110 and a back-end data relay device 120 connected to the data acquisition device 110.

[0036] The data acquisition device 110 includes a main control module 112, a first signal isolation module 114, and a first wireless communication module 116 connected in sequence; wherein, the main control module 112 is connected to the non-isolated side module of the first signal isolation module 114; and the isolated side module of the first signal isolation module 114 is connected to the first wireless communication module 116.

[0037] The data relay device 120 includes a second signal isolation module 122 and a second wireless communication module 124; wherein, the non-isolated side module of the second signal isolation module 122 is used to connect to the host terminal 200; the isolated side module of the second signal isolation module 122 is connected to the second wireless communication module 124.

[0038] The first wireless communication module 116 and the second wireless communication module 124 are connected via a wireless communication line.

[0039] The data acquisition device 110 can be used to collect, process and transmit data from various sensors at the well site. It can be a hub box connected to the sensors at the well site, or a data acquisition board or programmable logic controller, etc.

[0040] The data relay device 120 can be used to perform data isolation, encapsulation, forwarding and other processing between the data acquisition device 110 and the host terminal 200 at the back end. It can be a ground box placed in the instrument room and connected to the host terminal 200 in the well site scenario, or a router or gateway, etc.

[0041] In the well site scenario, the main control module 112 uses a serial communication protocol for communication. The main control module 112 can be any of the following: a microcontroller unit (MCU), a field-programmable gate array (FPGA), or an application-specific integrated circuit (ASIC).

[0042] The isolation side module of a signal isolation module is the isolation side circuit of the signal isolation module, while the non-isolation side module is the non-isolation side circuit of the signal isolation module. A signal isolation module can be a signal isolation chip, a coupler, or an isolator, etc.

[0043] The wireless communication module can be any of the following: a wireless communication chip, an integrated wireless module, etc.

[0044] The host terminal 200 is a background control system (such as an industrial computer, server, or back-end computer), which is responsible for receiving, processing, and storing data from field devices, or issuing control commands.

[0045] Specifically, the industrial data communication system 100 applied in well site scenarios mainly consists of a field-end data acquisition device 110 and a back-end data relay device 120, with the data relay device 120 connected to the data acquisition device 110. The data acquisition device 110 includes a main control module 112, a first signal isolation module 114, and a first wireless communication module 116. The main control module 112 can be used to acquire and perform preliminary processing (such as data filtering and protocol conversion) on data from downhole operations, and interacts with the first signal isolation module 114 using a serial communication protocol.

[0046] The first signal isolation module 114 employs electrical isolation technology to isolate the data transmitted between the main control module 112 and the first wireless communication module 116. The non-isolated side of the first signal isolation module 114 is connected to the main control module 112, and the isolated side is connected to the first wireless communication module 116 to achieve signal isolation and data transmission. Specifically, the data transmission end (or data transmission port or data transmission pin) of the non-isolated side of the first signal isolation module 114 is connected to the data transmission end of the main control module 112, and the data transmission end of the isolated side is connected to the data transmission end of the first wireless communication module 116. The first wireless communication module 116 can be used to perform protocol conversion between the serial communication protocol and the wireless communication protocol used by the main control module 112.

[0047] The data relay device 120 includes a second signal isolation module 122 and a second wireless communication module 124 connected together. The second signal isolation module 122 also employs electrical isolation technology to isolate the data transmitted between the second wireless communication module 124 and the host terminal 200. The non-isolated side module of the second signal isolation module 122 is connected to the host terminal 200 for data interaction, while the isolated side module is connected to the second wireless communication module 124 to achieve signal isolation and data transmission. Specifically, the data transmission end of the non-isolated side module of the second signal isolation module 122 is connected to the data transmission end of the host terminal 200, and the data transmission end of the isolated side module is connected to the data transmission end of the second wireless communication module 124. The second wireless communication module 124 can be used to perform protocol conversion between the communication protocol used by the host terminal 200 and the wireless communication protocol.

[0048] The first wireless communication module 116 and the second wireless communication module 124 are connected via a wireless communication line so that the first wireless communication module 116 and the second wireless communication module (that is, the data acquisition device 110 and the data relay device 120) can communicate wirelessly.

[0049] In some embodiments, the main control module 112 may adopt the UART (Universal Asynchronous Receiver / Transmitter) communication protocol; the first wireless communication module 116 and the second wireless communication module 124 may communicate in the 2.4GHz frequency band.

[0050] It should be noted that the main control module 112 can also use I. 2 Communication protocols include C (Inter-Integrated Circuit), SPI (Serial Peripheral Interface), and CAN (Controller Area Network). The first wireless communication module 116 and the second wireless communication module 124 can communicate using any of the following wireless communication methods: Bluetooth, LoRa (Long Range Radio), Wi-Fi (Wireless Fidelity), or ZigBee. Furthermore, the first wireless communication module 116 and the second wireless communication module 124 can also communicate using other frequency bands, such as 433MHz, 5GHz, 868MHz, and 915MHz. The specific frequency band can be determined based on the actual application scenario or requirements, and this specification does not impose specific limitations.

[0051] In the above embodiments, a dual signal isolation design is employed. A first signal isolation module is installed in the field data acquisition device to isolate the electrical connection between the main control module and the first wireless communication module. A second signal isolation module is installed in the back-end data relay device to isolate the electrical connection between the host device and the second wireless communication module. This improves the system's electrical safety, enabling stable operation under complex well site conditions and enhancing its anti-interference capabilities. The wireless communication design reduces the physical cabling in well site scenarios, thus mitigating data communication interruptions and security issues caused by physical cable damage in complex environments. This allows for greater flexibility in adapting to different terrains and working conditions, improving system robustness and scalability. The integrated "isolation + wireless" design addresses the security and reliability challenges of data transmission in well site scenarios, improving data transmission quality and enabling reliable wireless communication between the field data acquisition device and the back-end data relay device. It also offers deployment flexibility and cost advantages, providing crucial technical support for the implementation of the Industrial Internet of Things (IIoT) in the energy sector.

[0052] In some implementations, reference Figure 2 As shown, the host terminal 200 and the non-isolated side module of the second signal isolation module 122 are connected through the communication protocol conversion module 210.

[0053] The host terminal 200 and the main control module 112 in the field data acquisition device 110 use different communication protocols. The communication protocol conversion module 210 is used to solve the protocol mismatch problem, specifically to convert between the first communication protocol (or first interface protocol) of the host terminal 200 and the second communication protocol (or second interface protocol) of the main control module 112.

[0054] Specifically, the data transmission end of the non-isolated side module of the second signal isolation module 122 is connected to one side of the data transmission end of the communication protocol conversion module 210, and the other side of the data transmission end of the communication protocol conversion module 210 is connected to the host end 200.

[0055] The isolation side module of the second signal isolation module 122 receives and processes the data transmitted by the second wireless communication module 124. The isolation side module then transmits the processed data to the non-isolated side module, which in turn sends data conforming to the second communication protocol format requirements to the communication protocol conversion module 210. The communication protocol conversion module 210 performs protocol conversion on the data sent by the non-isolated side module of the second signal isolation module 122 to convert it into data conforming to the format requirements of the first communication protocol of the host terminal 200, and then sends the converted data to the host terminal 200.

[0056] The communication protocol conversion module 210 receives data from the host terminal 200 that meets the requirements of the first communication protocol format, and converts it to meet the requirements of the second communication protocol format. The communication protocol conversion module 210 sends the converted data to the non-isolated side module of the second signal isolation module 122, where the non-isolated side module processes the data and transmits it to the isolated side module, which then sends the processed data to the second wireless communication module 124.

[0057] In some embodiments, the communication protocol conversion module 210 may be a module (e.g., a protocol conversion chip or integrated circuit) disposed in the data relay device 120.

[0058] In other embodiments, the communication protocol conversion module 210 may also be a module (e.g., a bridge, protocol extender, etc.) that is independently set between the data relay device 120 and the host 200.

[0059] It should be noted that the communication protocol used by the host 200 can be determined according to the actual application scenario or requirements, such as any one of the USB (Universal Serial Bus) protocol or Ethernet protocol, and this manual does not make a specific limitation.

[0060] In some implementations, the communication protocol conversion module 210 specifically adopts a USB to serial port chip.

[0061] Specifically, the host terminal 200 uses the USB protocol to interact with the communication protocol conversion module 210, and the second signal isolation module 122 uses the serial communication protocol to interact with the communication protocol conversion module 210. The communication protocol conversion module 210 is a USB-to-serial chip used to convert between the USB protocol and the serial communication protocol.

[0062] In some embodiments, the communication protocol conversion module 210 is a USB-to-serial chip disposed in the data transfer device 120. Further, the main control module 112 adopts the UART protocol, and the communication protocol conversion module 210 is a USB-to-UART serial chip in the data transfer device 120.

[0063] In the above embodiments, considering that modern industrial host computers (such as industrial control computers, portable laptops, etc.) are generally equipped with USB interfaces, and the non-isolated side of the second signal isolation module of the data transfer device often uses a serial port (because the serial port has strong anti-interference ability and simple wiring in the industrial environment, and is suitable for short-distance reliable communication), using a USB to serial port chip as a communication protocol conversion module can directly utilize the USB interface of the host computer without additional hardware expansion, and can improve the system's compatibility with different serial communication protocols, and reduce system cost and size.

[0064] In some implementations, the communication protocol conversion module 210 operates at voltages of 3.3 volts and 5 volts.

[0065] In some situations, traditional industrial equipment, USB interfaces, and microcontrollers widely use 5V operating voltage, while some modern microcontrollers, sensors, and wireless communication modules use 3.3V operating voltage. This is because 3.3V systems typically have lower power consumption, making them suitable for miniaturized, low-power devices and IoT applications. Communication protocol conversion modules that support both 3.3V and 5V operating voltages can meet the access requirements of 5V devices and newer 3.3V devices in well site scenarios, ensuring efficient collaboration between devices with different voltage standards and improving the overall system's flexibility and scalability.

[0066] In some embodiments, the communication protocol conversion module 210 specifically adopts a USB to UART serial port chip of model CH340N, which supports two operating voltages: 3.3V and 5V.

[0067] It should be noted that if other models of communication protocol conversion chips meet the needs of actual application scenarios, other models of chips can also be selected.

[0068] In some implementations, reference Figure 3 As shown, the data acquisition device 110 further includes a first power isolation module 310, the power output terminal of which is connected to the power input terminal of the first wireless communication module 116. The data relay device 120 further includes a second power isolation module 320, the power output terminal of which is connected to the power input terminal of the second wireless communication module 124.

[0069] The power isolation module is used to electrically isolate the input power supply from the output power supply through isolation technology.

[0070] It is understood that the power output terminal of the first power isolation module 310 is located in the isolation side circuit of the first power isolation module 310, and the power output terminal of the second power isolation module 320 is located in the isolation side circuit of the second power isolation module 320.

[0071] Specifically, the first power isolation module 310 is disposed within the data acquisition device 110. The power output terminal of the first power isolation module 310 is connected to the power input terminal of the first wireless communication module 116. It can be used to isolate the first wireless communication module 116 from the main power supply network, prevent noise, surges or other electrical interference on the power line from affecting the operation of the first wireless communication module 116, provide a safe, stable and clean power supply for the first wireless communication module 116, and ensure the reliability and stability of the first wireless communication module 116.

[0072] The second power isolation module 320 is installed inside the data relay device 120. The power output terminal of the second power isolation module 320 is connected to the power input terminal of the second wireless communication module 124. It can be used to isolate the second wireless communication module 124 from the main power supply network, provide the second wireless communication module 124 with a safe, stable and clean power supply, and ensure the reliable operation of the second wireless communication module 124.

[0073] It should be noted that the power input terminal on the non-isolated side of the first power isolation module 310 and the power input terminal on the non-isolated side of the second power isolation module 320 are each connected to a corresponding power supply (non-isolated power supply). The power supply connected to the power input terminal of the first power isolation module 310 can be the same as the power supply connected to the non-isolated side power input terminal of the first signal isolation module 114, and the power supply connected to the power input terminal of the second power isolation module 320 can be the same as the power supply connected to the non-isolated side power input terminal of the second signal isolation module 122.

[0074] The first power isolation module 310 and the second power isolation module 320 can each adopt any one of the following: transformer, coupler, power isolation chip, etc., without specific limitations in this specification.

[0075] In the above embodiments, introducing a power isolation module into the data acquisition device and the data relay device not only enhances the system's anti-interference capability and stability but also significantly improves the security and reliability of the entire data transmission link. This is crucial for ensuring efficient and reliable wireless communication in complex and harsh industrial environments.

[0076] In some implementations, the maximum output power of both the first power isolation module 310 and the second power isolation module 320 is 1 watt.

[0077] In some cases, industrial-grade wireless communication modules (such as those based on the 2.4GHz or Sub-1GHz frequency bands) typically consume power ranging from several hundred milliwatts to 1 watt when transmitting and receiving data. Therefore, using a power isolation module with a maximum output power of 1 watt can meet the needs of most wireless communication modules without requiring additional design margins. This avoids both performance degradation due to insufficient power and energy waste due to excessive power, while also preventing overheating and ensuring stable long-term operation of the wireless communication module. This is particularly suitable for well site monitoring scenarios requiring low power consumption and high stability.

[0078] In some embodiments, both the first power isolation module 310 and the second power isolation module 320 employ power isolation chips. Further, both the first power isolation module 310 and the second power isolation module 320 specifically employ a power isolation chip of model B0505S-1WR3.

[0079] It should be noted that if other models of power isolation chips meet the requirements of the actual application scenario, other models of chips can also be selected.

[0080] In some implementations, reference Figure 4 As shown, the data acquisition device 110 further includes a first voltage regulator module 410. The power output terminal of the first power isolation module 310 is also connected to the power input terminal of the first voltage regulator module 410, and the power output terminal of the first voltage regulator module 410 is connected to the power input terminal of the isolation side module of the first signal isolation module 114. The data relay device 120 further includes a second voltage regulator module 420. The power output terminal of the second power isolation module 320 is also connected to the power input terminal of the second voltage regulator module 420, and the power output terminal of the second voltage regulator module 420 is connected to the power input terminal of the isolation side module of the second signal isolation module 122.

[0081] The voltage regulator module is used to further stabilize the voltage output based on the isolated power supply, so as to provide a stable power supply to the isolation side module of the corresponding signal isolation module, ensuring that the wireless communication module operates within a safe and stable voltage range.

[0082] Specifically, the first voltage regulator module 410 is located in the data acquisition device 110. The power input terminal of this module is connected to the power output terminal of the first power isolation module 310 to receive the power after isolation processing by the first power isolation module 310 and perform voltage regulation processing on it. The power output terminal of the first voltage regulator module 410 is connected to the power input terminal of the isolation side module of the first signal isolation module 114 to provide the isolation side module of the first signal isolation module 114 with a stable isolation power supply that meets the requirements.

[0083] The second voltage regulator module 420 is located in the data relay device 120. The power input terminal of this module is connected to the power output terminal of the second power isolation module 320 to receive the power after it has been isolated by the second power isolation module 320 and to regulate its voltage. The power output terminal of the second voltage regulator module 420 is connected to the power input terminal of the isolation side module of the second signal isolation module 122 to provide the isolation side module of the second signal isolation module 122 with a stable isolated power supply that meets the requirements.

[0084] In some embodiments, if the voltage input to the power input terminal of the voltage regulator module is greater than the voltage required by the isolation side of the corresponding signal isolation module, the voltage regulator module can also be used to step down the received voltage. Similarly, if the voltage input to the power input terminal of the voltage regulator module is less than the voltage required by the isolation side of the corresponding signal isolation module, the voltage regulator module can also be used to boost the received voltage.

[0085] It should be noted that the first voltage regulator module 410 and the second voltage regulator module 420 can each adopt any one of the following: linear regulator, switching regulator, buck-boost converter, etc., which can be determined according to the actual application scenario or requirements.

[0086] In the above embodiments, the signal isolation module is ensured to operate under a stable voltage through dual protection of power isolation and voltage regulation, reducing device wear caused by power supply problems and helping to improve the stability and reliability of the system.

[0087] In some implementations, the output voltage of both the first voltage regulator module 410 and the second voltage regulator module 420 is 3.3 volts.

[0088] In some cases, particularly in low-power applications, signal isolation chips and other electronic devices commonly use 3.3V as their standard operating voltage, which significantly reduces system power consumption. Setting the output voltage of the voltage regulator module to 3.3V can directly meet the power supply requirements of most signal isolation modules without the need for additional voltage conversion circuits. This simplifies system design, improves compatibility between different modules, and meets low-power requirements.

[0089] In some embodiments, both the first voltage regulator module 410 and the second voltage regulator module 420 employ LDO (Low Dropout Regulator) chips. Further, both the first voltage regulator module 410 and the second voltage regulator module 420 may employ an LM1117S-3.3 LDO chip with a fixed output voltage of 3.3V.

[0090] It should be noted that if other models of voltage regulator chips meet the requirements of the actual application scenario, other models of chips can also be selected.

[0091] In some implementations, the maximum data rate of both the first signal isolation module 114 and the second signal isolation module 122 is 2 megabits per second.

[0092] In some situations, and in many industrial and communication scenarios, a data rate of 2 Mbps can support low- to medium-speed data transmission needs, such as sensor data acquisition in industrial automation, status monitoring and control command transmission in IoT devices, and real-time data uploading in well site monitoring systems. At the same time, the lower data rate (2 Mbps) helps improve signal immunity, especially in complex industrial environments where high-frequency signals are more susceptible to electromagnetic interference. A lower frequency reduces the bit error rate, ensuring the reliability of data transmission by the signal isolation module.

[0093] In some embodiments, both the first signal isolation module 114 and the second signal isolation module 122 may employ digital isolation chips. Further, both the first signal isolation module 114 and the second signal isolation module 122 may specifically employ a digital isolation chip of model ADUM1201BRZ with a maximum data rate of 2Mbps.

[0094] It should be noted that if other types of signal isolation chips meet the requirements of the actual application scenario, other types of chips can also be selected.

[0095] In some implementations, the maximum serial port baud rate of the first wireless communication module 116 and the second wireless communication module 124 is 115200 bits / second, and the air rate sets of the first wireless communication module 116 and the second wireless communication module 124 both include 250 kilobits / second, 1 megabit / second, and 2 megabit / second.

[0096] In some situations, 115200 bits per second is one of the commonly used baud rates in serial communication. Many industrial devices, sensors, and other data acquisition or processing equipment support this baud rate when conducting serial communication. This setting allows for better compatibility between the wireless communication module and other devices, facilitating data interaction and transmission. At the same time, a baud rate of 115200 bits per second strikes a good balance between stability and cost while ensuring a certain data transmission speed. In industrial environments where signal interference is complex, choosing this baud rate can guarantee reliable data transmission without significantly increasing cost or hardware complexity.

[0097] Furthermore, offering multiple air rate options allows wireless communication modules to have greater flexibility and compatibility, adapting to different wireless communication standards and protocols, as well as various industrial equipment and systems. 250 kilobits per second is suitable for scenarios with high transmission distance requirements, relatively small data volumes, and strict power consumption requirements; 1 megabit per second is a more balanced choice, satisfying certain data transmission speed requirements while achieving a good balance between transmission distance and power consumption; 2 megabits per second is suitable for scenarios with high data transmission speed requirements, relatively short transmission distances, and where power consumption is not a primary consideration.

[0098] In some embodiments, both the first wireless communication module 116 and the second wireless communication module 124 may employ a wireless communication chip. Further, both the first wireless communication module 116 and the second wireless communication module 124 may employ a wireless communication chip of model E34-2G4H20D.

[0099] For example, refer to Figure 5a As shown, this specification provides a long-range wireless communication system with isolation function for use in well sites, including a hub box at the field end (corresponding to the data acquisition device in this specification), a ground box at the back end (corresponding to the data relay device in this specification), and a PC terminal at the back end.

[0100] The hub includes an MCU (corresponding to the main control module in this specification), isolation modules for signal isolation and power isolation (including the first signal isolation module, the first power isolation module, and the first voltage regulator module in this specification), and a first wireless communication module. The MCU and the first signal isolation module are connected via a UART signal line (denoted as UART2 in the figure) to transmit data using the UART protocol.

[0101] The ground box includes a second wireless communication module, an isolation module for signal and power isolation (including the second signal isolation module, second power isolation module, and second voltage regulator module as described in this specification), and a USB conversion chip (corresponding to the communication protocol conversion module as described in this specification). The second signal isolation module and the USB conversion chip are connected via a UART signal line (denoted as UART1 in the figure) to transmit data using the UART protocol. The USB conversion chip is connected to a PC, and the data transmitted between the USB conversion chip and the PC meets the requirements of the USB protocol.

[0102] The first wireless communication module of the hub box communicates with the second wireless communication module of the ground box via a 2.4G antenna, with the ISM communication frequency band being 2.4GHz.

[0103] Therefore, the wireless module of the hub box is connected to the main control MCU, and the wireless module of the ground box is connected to the PC, thereby realizing communication between the PC and the hub box.

[0104] In the above example, the specific model of the MCU is STM32F407VET6; both the first and second signal isolation modules specifically use the ADUM1201BRZ digital isolation chip with a maximum data rate of 2Mbps; both the first and second wireless communication modules specifically use the E34-2G4H20D wireless communication chip, which has a maximum serial port baud rate of 115200, supports the standard 2.4GHz frequency band, and offers three different air speeds: 250kbps, 1Mbps, and 2Mbps. The lower the air speed, the longer the transmission distance; the USB conversion chip specifically uses the CH340N USB to UART chip, which supports both 3.3V and 5V operating voltages.

[0105] refer to Figure 5b As shown, the specific structure of the hub's wireless communication circuit is as follows: The data transmission terminal (corresponding to the VOA and VIB pins in the diagram, i.e., pins 2 and 3 of chip U7) of the non-isolated side circuit of the ADUM1201BRZ isolation chip (denoted as chip U7) is connected to the MCU via the UART2_RX and UART2_TX signal lines; the power input terminal of this non-isolated side circuit (corresponding to the power pin VDD1 in the diagram, i.e., pin 1 of chip U7) is connected to a 3.3V power supply. This power supply is decoupled through a capacitor C16 (100nF (nanofarad)) to filter out high-frequency noise in the power supply and ensure power stability. This power supply, together with a 10kΩ resistor R3, also serves as a current limiter or pull-up resistor on the UART2_RX line; the GND1 pin of this non-isolated side circuit (i.e., pin 4 of chip U7) is grounded. It should be noted that UART2_RX is the receive signal line from the MCU's perspective, and UART2_TX is the transmit signal line from the MCU's perspective.

[0106] The data transmission terminals of the isolation side circuit of chip U7 (corresponding to the right side of the dotted line in the figure) (i.e., the VIA and VOB pins in the figure, i.e., pins 7 and 6 of chip U7) are connected to the data transmission terminals of the wireless module E34-2G4H20D (denoted as chip U8) (i.e., the TXD and RXD pins in the figure, i.e., pins 4 and 3 of chip U8) via the TX2_2.4G and RX2_2.4G signal lines for isolated signal transmission. The power input terminal of this isolation side circuit (i.e., the power pin VDD2 in the figure, i.e., pin 8 of chip U7) is connected to an ISO_3.3V isolation power supply, which is decoupled through capacitor C17 (100nF). The GND2 pin of this isolation side circuit (i.e., pin 5 of chip U7) is used for grounding after isolation to ensure that the grounding of the two isolated circuits is independent and to enhance the isolation effect. It should be noted that TX2_2.4G is the transmit signal line from the perspective of chip U8, and RX2_2.4G is the receive signal line from the perspective of chip U8. Since the GND pins of each chip are used for grounding, they will not be discussed further below.

[0107] The mode configuration pins M0 and M1 of chip U8 (i.e., pins 1 and 2 of chip U8) are grounded. The AUX auxiliary pin (i.e., pin 5 of chip U8) is used to receive the AUX (Auxiliary) signal. The power input terminal (i.e., the power pin VCC in the diagram, i.e., pin 6 of chip U8) is connected to an ISO_5V isolated power supply, which is decoupled through capacitor C18 (100nF). Pins 8, 9, and 10 of chip U8 are unused.

[0108] refer to Figure 5c As shown, the specific structure of the ground box wireless communication circuit is as follows: USB interface J1 connects to the external device PC. J1 is connected to the USB signal transmission terminal (corresponding to pins UD+ and UD- in the figure, i.e., pins 1 and 2 of chip U6) of USB conversion chip CH340N (denoted as chip U6) via USB signal lines (corresponding to the 2.4G_D+ and 2.4G_D- signal lines in the figure), enabling chip U6 to receive USB signals from the outside and convert them into serial port signals.

[0109] An external capacitor C13 (100nF) is connected to pin V3 of chip U6 (i.e., pin 8 of chip U6) for power supply filtering. RXD (pin 7) and TXD (pin 6) are the serial port receive and transmit pins, respectively, and are connected to the data transmission terminals (i.e., the VOA pin and VIB pin in the diagram, i.e., pins 2 and 3 of chip U4) of the non-isolated side circuit of the isolation chip ADUM1201BRZ (denoted as chip U4) (corresponding to the part to the left of the dotted line in the diagram) via the UART1_RX and UART1_TX signal lines. Pin RTS# (i.e., pin 3) can be used for hardware flow control, etc. It should be noted that UART1_RX and UART1_TX are defined from the perspective of chip U6.

[0110] The power input terminal of the non-isolated side circuit of chip U4 (i.e., the power pin VDD1 in the figure, which is also pin 1 of chip U4) is connected to a 5V power supply. This power supply is decoupled through capacitor C11 (100nF). This power supply, together with a resistor R1 with a resistance of 10kΩ, plays the role of current limiting or pull-up on the UART1_RX line.

[0111] For a description of the isolation side circuit of chip U4 (corresponding to the part to the right of the dotted line in the figure) and the wireless module E34-2G4H20D (denoted as chip U5), please refer to the description of the isolation side circuit of chip U7 and chip U8 above. Specific details will not be repeated here.

[0112] Based on the aforementioned junction box and ground box, the specific working principle of the long-distance wireless communication system with isolation function provided in this manual is as follows: The ADUM1201BRZ chip is connected to the MCU via the UART2 signal line, enabling the MCU to communicate with the wireless module E34-2G4H20D in UART mode. To reduce interference from digital circuits to wireless communication, the ADUM1201BRZ chip is used to isolate the UART signal transmitted between the MCU and the wireless module. The wireless module transmits data to the ground box via a 2.4G antenna. The specific model of the 2.4G antenna is TX2400-TB-300, which supports the frequency band of 2.4-2.5GHz, has a gain of 5dBi (decibels relative to isotropic), and comes with a 3-meter feedback cable and a suction cup.

[0113] After receiving data from the hub box, the ground box converts the data into UART format. After passing through the digital isolation chip ADUM1201BRZ, the data is transmitted to the CH340N chip. The CH340N chip converts the UART signal into a USB signal and sends it to the PC, thereby realizing reliable communication between the PC at the back end and the MCU of the hub box at the field end.

[0114] In addition, both the first and second power isolation modules use a power isolation chip of model B0505S-1WR3 with a maximum output power of 1W; both the first and second voltage regulator modules use an LDO chip of model LM1117S-3.3 with a fixed output voltage of 3.3V.

[0115] refer to Figure 5d As shown, taking the second power isolation module in the ground box as an example, the power input terminal VIN (i.e., pin 2 of chip U2) of the non-isolated side circuit of power chip B0505S-1WR3 (denoted as chip U2) (corresponding to the left of the dashed line of chip U2 in the figure) is connected to a +5V input power supply, which is filtered by capacitor C5 (4.7uF (microfarad)). The power output terminal +Vo of the isolated side circuit of chip U2 (corresponding to the right of the dashed line of chip U2 in the figure) outputs the isolated ISO_5V power supply, and capacitor C6 (10uF / 50V) is the output filter capacitor used to stabilize the output voltage.

[0116] refer to Figure 5e As shown, taking the second power isolation module in the ground box as an example, the LDO chip LM1117S-3.3 (denoted as chip U3) is used to convert the input voltage into a stable 3.3V output voltage. In this circuit, the input is the isolated ISO_5V, and the output is ISO_3.3V. Specifically, the power input terminal Vin of chip U3 (i.e., pin 3 of chip U3) is connected to the ISO_5V input power supply (i.e., the Vin pin of chip U3 is connected to the +Vo pin of chip U2). C7 (10uF / 50V) and C8 (100nF) are input filter capacitors used to filter out power ripple. The power output terminal Vout (i.e., pin 2 of chip U3) outputs a stable ISO_3.3V voltage. C9 (10uF / 50V) and C10 (100nF) are output filter capacitors to further stabilize the output voltage. TAB (i.e., pin 4 of chip U3) can play an auxiliary role in heat dissipation, etc.

[0117] More specifically, the output voltage ISO_5V of chip U2 can power the wireless communication module in the aforementioned ground box. Specifically, the power output terminal +Vo of the isolation side circuit of the power isolation chip B0505S-1WR3 is connected to the power input terminal VCC of the wireless module E34-2G4H20D in the ground box. This power output terminal +Vo is also connected to the power input terminal Vin of chip U3.

[0118] The power output terminal Vout of chip U3 is connected to the power input terminal VDD2 of the digital isolation chip ADUM1201BRZ in the aforementioned ground box to provide a stable voltage for the data isolation chip.

[0119] The specific descriptions of the power isolation chip B0505S-1WR3 and the voltage regulator module LM1117S-3.3 in the hub box are similar to those described above, and will not be repeated here.

[0120] Based on the aforementioned power isolation chip and voltage regulator module, the working principle of power isolation in the long-distance wireless communication system with isolation function provided in this manual is as follows: The +5V power signal passes through the isolation power module B0505S-1WR3 to generate an isolated power supply ISO_5V, which is used to power the wireless communication module. The isolated power supply ISO_5V is input to the voltage regulator module, so that ISO_5V is regulated by LM1117S-3.3 to generate a regulated isolated power supply ISO_3.3V, which is used to power the digital isolation chip and can also be used to limit current or pull up on relevant signal lines.

[0121] The wireless communication scheme implemented in the industrial data communication system in the above example demonstrates stable and reliable communication with a low packet loss rate. It can operate for 100 hours at a communication distance of 70 meters with no more than 5 packet losses. By selecting a wireless module and antenna, the wireless module can be integrated onto a circuit board inside the box, resulting in a smaller size and reducing the physical cabling required in the well site. This allows for more flexible adaptation to different terrains and working conditions, thereby improving the system's robustness and scalability. Due to the low power consumption of the selected wireless module, it can maintain stable operation for a considerable period when used with a battery.

[0122] It should be noted that, in the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that the specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this utility model. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0123] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0124] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0125] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. An industrial data communication system, characterized in that, Applied to well sites, the industrial data communication system includes a field-end data acquisition device and a back-end data relay device connected to the data acquisition device. The data acquisition device includes a main control module, a first signal isolation module, and a first wireless communication module connected in sequence; wherein, the main control module is connected to the non-isolated side module of the first signal isolation module; and the isolated side module of the first signal isolation module is connected to the first wireless communication module. The data relay device includes a second signal isolation module and a second wireless communication module; wherein, the non-isolated side module of the second signal isolation module is used to connect to the host; the isolated side module of the second signal isolation module is connected to the second wireless communication module; The first wireless communication module and the second wireless communication module are connected via a wireless communication line.

2. The industrial data communication system according to claim 1, characterized in that, The host terminal and the non-isolated side module of the second signal isolation module are connected through a communication protocol conversion module.

3. The industrial data communication system according to claim 2, characterized in that, The communication protocol conversion module specifically uses a USB to serial port chip.

4. The industrial data communication system according to claim 2, characterized in that, The communication protocol conversion module operates at voltages of 3.3 volts and 5 volts.

5. The industrial data communication system according to claim 1, characterized in that, The data acquisition device further includes a first power isolation module, wherein the power output terminal of the first power isolation module is connected to the power input terminal of the first wireless communication module. The data relay device further includes a second power isolation module, the power output terminal of which is connected to the power input terminal of the second wireless communication module.

6. The industrial data communication system according to claim 5, characterized in that, The maximum output power of both the first power isolation module and the second power isolation module is 1 watt.

7. The industrial data communication system according to claim 5, characterized in that, The data acquisition device further includes a first voltage regulator module, the power output terminal of the first power isolation module is also connected to the power input terminal of the first voltage regulator module, and the power output terminal of the first voltage regulator module is connected to the power input terminal of the isolation side module of the first signal isolation module. The data relay device further includes a second voltage regulator module. The power output terminal of the second power isolation module is also connected to the power input terminal of the second voltage regulator module, and the power output terminal of the second voltage regulator module is connected to the power input terminal of the isolation side module of the second signal isolation module.

8. The industrial data communication system according to claim 7, characterized in that, The output voltage of both the first voltage regulator module and the second voltage regulator module is 3.3 volts.

9. The industrial data communication system according to any one of claims 1 to 8, characterized in that, The maximum data rate of both the first signal isolation module and the second signal isolation module is 2 megabits per second.

10. The industrial data communication system according to any one of claims 1 to 8, characterized in that, The maximum serial port baud rate of both the first and second wireless communication modules is 115200 bits / second, and the air rate sets of both the first and second wireless communication modules include 250 kilobits / second, 1 megabit / second, and 2 megabit / second.

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