Mining intrinsic safety type wireless deviation sensor

Abstract

The utility model relates to a mining intrinsic safety type wireless deviation sensor, which belongs to the technical field of mining electrical equipment and comprises a single chip microcomputer control module, a power supply module, a sensor acquisition module, a wireless communication module and a key input module, the power supply module, the sensor acquisition module, the wireless communication module and the case input module are all connected with the single-chip microcomputer control module, the power supply module comprises a battery power supply circuit and an external charging circuit, and the battery power supply circuit and the external charging circuit are both connected with the single-chip microcomputer control module. According to the application, two modes of battery power supply and Type-C / USB direct charging are adopted, and the LGS4084HB6 charging chip and the TPS62745 voltage reduction chip are combined, so that the use convenience and flexibility of the sensor are improved, the low power consumption performance is further enhanced through efficient charging management and electric energy conversion, and the application range is wide. And meanwhile, the use of the intrinsic safety type battery ensures the safety in a mine inflammable and explosive environment.

Description

An intrinsically safe wireless belt misalignment sensor for mining applications Technical Field

[0001] This application relates to the technical field of mining electrical equipment, and in particular to an intrinsically safe wireless deviation sensor for mining applications. Background Technology

[0002] In mining operations, belt conveyors are crucial material transport equipment, and their operational stability directly impacts mine production efficiency and safety. Belt misalignment is a common fault in belt conveyors. If not detected and addressed promptly, it can lead to serious problems such as belt tearing and material spillage, and even safety accidents. Mining belt misalignment sensors can monitor the belt's operating status in real time.

[0003] Traditional mine belt misalignment sensors mostly use wired connections, requiring the laying of numerous cables. This not only increases installation costs but also makes maintenance difficult, especially in complex mining environments where cables are easily damaged, affecting the sensor's normal operation. Currently, wireless belt misalignment sensors are gradually being adopted. They eliminate the need for cable laying, offering convenient installation and high flexibility. However, existing wireless mine belt misalignment sensors require 24 / 7 real-time monitoring of the conveyor belt's operating status, which can lead to excessive power consumption, resulting in frequent battery replacements and wasted manpower and resources. Summary of the Invention

[0004] To address the aforementioned issues, this application provides an intrinsically safe wireless deviation sensor for mining applications.

[0005] The intrinsically safe wireless deviation sensor for mining applications provided in this application adopts the following technical solution:

[0006] A mine-use intrinsically safe wireless belt misalignment sensor includes a microcontroller control module, a power supply module, a sensor acquisition module, a wireless communication module, and a key input module. The power supply module (102), sensor acquisition module, wireless communication module, and key input module are all connected to the microcontroller control module. The power supply module includes a battery power supply circuit and an external charging circuit, both of which are connected to the microcontroller control module. A power switching circuit is included between the battery power supply circuit and the external charging circuit. The wireless communication module is used to realize wireless data transmission between the microcontroller control module and a host computer, and the sensor acquisition module is used to acquire belt misalignment signals.

[0007] By adopting the above technical solution, the sensor acquisition module detects the conveyor belt deviation and transmits the information to the microcontroller control module. The microcontroller control module transmits the deviation information to the host computer through the wireless communication module. The power module is divided into two parts: battery power supply and Type-C / USB direct charging.

[0008] Preferably, the power switching circuit includes a battery input Vin1, an external power input Vin2, a ground terminal GND, an output terminal Vout, a first transistor Q1, a second transistor Q2, a third transistor Q3, a first voltage divider resistor R41, and a second voltage divider resistor R42. The gate of the first transistor Q1 is connected to the battery input Vin1, its source is grounded, and its drain is connected to the output terminal Vout. The gate of the second transistor Q2 is connected to the ground terminal GND through the first resistor R41. The gate of the third transistor Q3 is connected to the ground terminal GND through the second resistor R42. The sources of the second transistor Q2 and the third transistor Q3 are respectively connected to the external power input Vin2 and the battery input Vin1, and their drains are connected to the output terminal Vout.

[0009] By adopting the above technical solution and through the coordinated configuration of transistors and resistors, automatic switching between two power inputs is achieved, and the stability of the output voltage is ensured.

[0010] Preferably, Q1 is an N-channel MOSFET, and Q2 and Q3 are P-channel MOSFETs.

[0011] Preferably, the resistance values ​​of the first resistor R41 and the second resistor R42 are 330 kΩ.

[0012] By adopting the above technical solution, resistors R41 and R42 (330KΩ) are used to limit the gate current and ensure stable control of the MOSFET.

[0013] Preferably, the external charging circuit includes a Type-C / USB interface circuit and a first voltage regulator circuit.

[0014] By adopting the above technical solution, the Type-C / USB interface allows users to power the sensor without removing the battery, thus improving ease of use.

[0015] Preferably, the battery power supply circuit includes a lithium battery and a step-down power supply chip, wherein the step-down power supply chip reduces the output voltage of the lithium battery.

[0016] By adopting the above technical solution and using a step-down chip, which has high power conversion efficiency, the battery voltage can be stably converted to 3.3V to power the sensor acquisition module, wireless communication module and microcontroller module, etc., while having low quiescent current characteristics, which helps to reduce the overall power consumption of the system.

[0017] Preferably, the external charging circuit and the battery power supply circuit are connected through a battery charging circuit.

[0018] By adopting the above technical solution and using a battery charging circuit, the battery's lifespan and charging safety are effectively guaranteed.

[0019] Preferably, the microcontroller control module uses an STM32L431R chip as the core controller, and the microcontroller control module also includes a reset circuit and a crystal oscillator circuit.

[0020] By adopting the above technical solution, the chip features low power consumption, enabling low-power management of the wireless deviation sensor, including wake-up and sleep functions. The STM32L431R chip integrates rich peripheral interfaces, facilitating communication and data processing with other modules. A reset circuit is used to reset the microcontroller when the sensor starts up or malfunctions, ensuring normal operation of the microcontroller. A crystal oscillator circuit provides a clock signal to the microcontroller, ensuring a stable operating frequency.

[0021] In summary, this application includes at least one of the following beneficial technical effects:

[0022] 1. This application achieves low-power management of the wireless deviation sensor by using the STM32L431R chip as the core controller of the microcontroller module, thereby extending battery life and reducing the frequency of battery replacement.

[0023] 2. A power switching circuit is adopted, which achieves automatic switching without external control signals through a gate grounding resistor: when power is connected to any input port, the corresponding P-channel MOSFET turns on because the gate-source voltage is negative, transmitting the input power to the output terminal. The circuit structure is simple and highly reliable.

[0024] 3. The power module adopts both battery power supply and Type-C / USB direct charging. Combined with the LGS4084HB6 charging chip and TPS62745 step-down chip, it not only improves the convenience and flexibility of the sensor, but also enhances the low power consumption performance through efficient charging management and power conversion. At the same time, the use of intrinsically safe batteries ensures safety in flammable and explosive environments in mines. Attached Figure Description

[0025] Figure 1 is a system principle block diagram of an intrinsically safe wireless deviation sensor for mining applications according to this application.

[0026] Figure 2 is a circuit diagram of the microcontroller control module of an intrinsically safe wireless deviation sensor for mining applications according to this application.

[0027] Figure 3 is a circuit diagram of the energy module of an intrinsically safe wireless deviation sensor for mining applications according to this application.

[0028] Figure 4 is a circuit diagram of the sensor acquisition module and the wireless communication module of an intrinsically safe wireless deviation sensor for mining applications according to this application.

[0029] Figure 5 is a schematic diagram of the power switching circuit of an intrinsically safe wireless deviation sensor for mining applications according to this application.

[0030] Explanation of reference numerals in the attached diagram: 101, Microcontroller control module; 102, Power supply module; 103, Sensor acquisition module; 104, Wireless communication module; 105, Key input module. Detailed Implementation

[0031] The present application will be further described in detail below with reference to Figures 1-5.

[0032] This application discloses an intrinsically safe wireless deviation sensor for mining applications. Referring to Figure 1, it includes a microcontroller control module 101, a power supply module 102, a sensor acquisition module 103, a wireless communication module 104, and a key input module 105. The power supply module 102, sensor module, wireless communication module 104, and key input module 105 are all connected to the microcontroller control module 101. The power supply module 102 includes a battery power supply circuit and an external charging circuit, both of which are connected to the microcontroller control module 101. A power switching circuit is included between the battery power supply circuit and the external charging circuit.

[0033] Referring to Figure 2, the microcontroller control module 101 is the core of the entire sensor and uses an STM32L431R microcontroller. This microcontroller has rich peripheral interfaces, including SPI, I2C, USART, ADC, etc., which can meet the connection and communication requirements with various modules.

[0034] The PA14 / JTCK-SWCLK, PA15 / JTDI / SPI3_NSS, PC10 / USART3_TX / SPI3_SCK, PC11 / USART3_RX / SPI3_MISO, and PC12 / SPI3_MOSI pins of the STM32L431R microcontroller are used to connect to the 104CC68-C1 wireless communication module to transmit data via the SPI interface. Specifically, PA15 serves as the NSS (chip select) signal for SPI3, PC10 as the SCK (clock) signal for SPI3, PC11 as the MISO (master-in, slave-out) signal for SPI3, and PC12 as the MOSI (master-out, slave-in) signal for SPI3, enabling SPI communication between the microcontroller and the 104CC68-C1 wireless communication module.

[0035] The PA3 / USART2_RX / ADC1_IN8 and PA4 / SPI1_NSS / ADC1_IN9 / DAC1_OUT1 pins are used to connect to the sensor acquisition module 103. PA3 and PA4 serve as ADC input pins, receiving the deviation signal output by the sensor acquisition module 103. The analog signal output by the sensor acquisition module 103 is conditioned and then input to the ADC pin of the microcontroller. The microcontroller converts the analog signal into a digital signal through its internal ADC converter for processing and analysis.

[0036] The button PWR_KEY of the button input module 105 is connected to the microcontroller's PB3 / JTDO / SPI3_SCK pin, and is connected to a 3V power supply via a pull-up resistor R17 (10KΩ). When the button is pressed, this pin is grounded, generating a low-level signal that triggers an external interrupt of the microcontroller, enabling power-on or wake-up functions. The MCU_KEY button is connected to another GPIO pin, PB4 / NJTRST / SPI3_MISO, which is also connected to the power supply via a pull-up resistor, used for functions such as reset or parameter setting.

[0037] The microcontroller's pins PC13 / WKUP2 / RTC_TAMP1, PC14 / OSC32_IN, and PC15 / OSC32_OUT are used to connect to external crystal oscillators and reset circuits, providing the microcontroller with a stable clock signal and reset function.

[0038] Referring to Figure 3, the power module 102 provides a stable power supply for the entire sensor, including both battery power and Type-C / USB charging.

[0039] The LGS4084HB6 charging chip is a high-efficiency lithium battery charging management chip that supports Type-C / USB interface input and features overcharge, over-discharge, overcurrent, and short-circuit protection. The VIN_SW pin of the Type-C interface J5 is connected to the input pin of the charging chip, and EN_VIN_SW is used to enable the charging chip. The output pin of the charging chip is connected to the battery B6B-XH to charge the battery. The battery voltage VBAT is stepped down by the TPS62745 buck converter to output 3.3V (3V³-1), which powers the various modules.

[0040] The TPS62745 step-down converter is a low-power, high-efficiency step-down converter capable of stepping down input voltage (such as a battery voltage of 3.7V) to 3.3V, meeting the operating voltage requirements of microcontrollers, sensors, wireless communication modules, etc. Its input pin connects to the battery's VBAT pin, and its output pin connects to a 3V3-1 circuit, providing a stable power supply to various modules.

[0041] The power module 102 also includes capacitors C4 (10uF), C16, C17, and C18 for filtering and stabilizing voltage to ensure power supply stability. Resistors R28 (10KΩ) and others are used for voltage division or current limiting to protect circuit components.

[0042] Referring to Figure 5, a power switching circuit is included between the battery power supply circuit and the external charging circuit. The power switching circuit includes a battery input Vin1, an external power input Vin2, a ground terminal GND, an output terminal Vout, a first transistor Q1, a second transistor Q2, a third transistor Q3, a first voltage divider resistor R41, and a second voltage divider resistor R42. Specifically, the gate of the first transistor Q1 is connected to the battery input Vin1, its source is grounded, and its drain is connected to the output terminal Vout. The second transistor Q2... The gate of transistor Q1 is connected to ground GND through the first resistor R41, and the gate of transistor Q3 is connected to ground GND through the second resistor R42. The sources of transistors Q2 and Q3 are connected to the external power input Vin2 and the battery input Vin1, respectively, and their drains are connected to the output terminal Vout. The output terminal Vout powers the microcontroller and the sensor. Transistor Q1 is an N-channel MOSFET, model 2N7002, while transistors Q2 and Q3 are both P-channel MOSFETs, model PMN50XP. The resistance values ​​of the first resistor R41 and the second resistor R42 are 330kΩ.

[0043] If the battery input Vin1 = 3.3V, Q1 turns on, which then pulls down the gate of Q3. Then Q1 also turns on. At this time, the voltage between the gate and source of Q2 is the turn-on voltage drop of Q3. Q2 turns off, the external power supply input Vin2 is disconnected, and Vout is powered by the battery input Vin1, Vout = 3.3V.

[0044] When the battery input Vin1 is disconnected, Q1 is off. Q2 is turned on because its gate is pulled down by R1. Q3 is also turned off because its gate is pulled up by R2. In the entire circuit, Q1 and Q3 are off. Vout is powered by the external power input Vin2, and Vout = 3.3V.

[0045] This achieves the following: when the battery input Vin1 = 3.3V, the voltage is output from the battery input Vin1 through Q3 regardless of whether the external power supply input Vin2 has voltage; when the battery input Vin1 is disconnected, the voltage is output from the external power supply input Vin2 through Q2.

[0046] Referring to Figure 4, the sensor acquisition module 103 includes a belt misalignment sensor and a signal conditioning circuit. The belt misalignment sensor is installed on both sides of the belt conveyor to detect the degree of belt misalignment. When the conveyor belt misaligns, the sensor converts the misalignment displacement into an electrical signal. This electrical signal is amplified and filtered by the signal conditioning circuit before being input to the ADC pin of the microcontroller.

[0047] The signal conditioning circuit includes an operational amplifier, resistors, and capacitors. It amplifies the weak signal output by the sensor while filtering out high-frequency noise and improving signal quality. The signal output by the sensor is divided by resistors such as R8 (47KΩ) and then input to the non-inverting input of the operational amplifier. The output of the operational amplifier is connected to the ADC pin of the microcontroller.

[0048] Referring to Figure 4, the 104CC68-C1 wireless communication module connects to the microcontroller via an SPI interface to achieve wireless data transmission. Its ANT pin is connected to the antenna for transmitting and receiving wireless signals. The DIO1 and DIO3 pins are connected to the microcontroller's GPIO pins to indicate communication status or receive control signals. The BUSY pin indicates whether the module is in a busy state; the microcontroller can determine whether data can be sent or received by detecting the level of this pin.

[0049] During connection, the CC68-C1's SPI interface pins MISO, MOSI, SCK, and NSS are connected to the corresponding pins PC11, PC12, PC10, and PA15 of the microcontroller's SPI3 interface, respectively, to achieve SPI communication. The microcontroller sends data to the wireless communication module 104 through the SPI interface, reads the received data from the wireless communication module 104, and transmits it to the host computer or receives instructions from the host computer through the antenna.

[0050] Referring to Figure 4, the key input module 105 includes a power button PWR_KEY and a function button MCU_KEY. The PWR_KEY button is connected to the GPIO pin of the microcontroller and the power supply through a diode 1N4148WS and resistors R15 (4.7KΩ) and R17 (10KΩ) to realize the power-on and wake-up functions. When the PWR_KEY button is pressed, the circuit is turned on, generating a trigger signal. After the microcontroller detects the signal, it wakes up from the sleep state and enters the working state.

[0051] The MCU_KEY button is used to perform functions such as reset and parameter setting. It is connected to a 3V power supply through a pull-up resistor. When pressed, it is grounded, generating a low-level signal that triggers the microcontroller's interrupt processing to achieve the corresponding function.

[0052] The implementation principle of a wireless deviation sensor for mining applications in this application is as follows:

[0053] Under normal operating conditions, the microcontroller is in running mode, acquiring sensor signals in real time, processing data, and transmitting it through the wireless communication module 104. When the sensor does not detect a deviation signal or receives a sleep command for a period of time, the microcontroller enters sleep mode, turning off the power to non-essential modules such as the wireless communication module 104 and the sensor acquisition module 103, leaving only the real-time clock (RTC) and wake-up circuit running to reduce power consumption.

[0054] The buttons in the button input module 105 can be used as wake-up sources. When the power button or a function button is pressed, a wake-up interrupt is triggered on the microcontroller, causing it to resume from sleep mode to running mode. Additionally, the sensor acquisition module 103 can also be set as a wake-up source. When a conveyor belt misalignment signal is detected, it wakes up the microcontroller for processing.

[0055] In normal mode, the mining sensor is powered by the built-in battery. When charging is required, the mining sensor is powered by an external charging circuit.

[0056] 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 mine-use intrinsically safe wireless deviation sensor, characterized in that: The intrinsically safe wireless belt misalignment sensor for mining includes a microcontroller control module (101), a power supply module (102), a sensor acquisition module (103), a wireless communication module (104), and a key input module (105). The power supply module (102), sensor acquisition module (103), wireless communication module (104), and key input module (105) are all connected to the microcontroller control module (101). The power supply module (102) includes a battery power supply circuit and an external charging circuit, both of which are connected to the microcontroller control module (101). A power switching circuit is included between the battery power supply circuit and the external charging circuit. The wireless communication module (104) is used to realize wireless data transmission between the microcontroller control module (101) and the host computer, and the sensor acquisition module (103) is used to collect the belt misalignment signal.

2. The mine-used intrinsic safety type wireless deviation sensor according to claim 1, characterized in that: The power switching circuit includes a battery input Vin1, an external power input Vin2, a ground terminal GND, an output terminal Vout, a first transistor Q1, a second transistor Q2, a third transistor Q3, a first voltage divider resistor R41, and a second voltage divider resistor R42. The gate of the first transistor Q1 is connected to the battery input Vin1, its source is grounded, and its drain is connected to the output terminal Vout. The gate of the second transistor Q2 is connected to the ground terminal GND through the first resistor R41, and the gate of the third transistor Q3 is connected to the ground terminal GND through the second resistor R42. The sources of the second transistor Q2 and the third transistor Q3 are connected to the external power input Vin2 and the battery input Vin1, respectively, and their drains are connected to the output terminal Vout.

3. The mine-used intrinsically safe wireless deviation sensor of claim 2, characterized in that: Q1 is an N-channel MOSFET, and Q2 and Q3 are P-channel MOSFETs.

4. The intrinsically safe wireless deviation sensor for mining applications according to claim 2, characterized in that: The resistance of the first resistor R41 and the second resistor R42 is 330 kΩ.

5. The intrinsically safe wireless deviation sensor for mining applications according to claim 1, characterized in that: The external charging circuit includes a Type-C / USB interface circuit and a first voltage regulator circuit.

6. The mine-used intrinsic safety type wireless deviation sensor according to claim 1, characterized in that: The battery power supply circuit includes a lithium battery and a step-down power supply chip, which reduces the output voltage of the lithium battery.

7. The mine-used intrinsically safe wireless deviation sensor of claim 1, characterized in that: The external charging circuit and the battery power supply circuit are connected through the battery charging circuit.

8. The intrinsically safe wireless deviation sensor for mining applications according to claim 1, characterized in that: The microcontroller control module (101) uses an STM32L431R chip as the core controller. The microcontroller control module (101) also includes a reset circuit and a crystal oscillator circuit.

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