A zigbee factory environment data acquisition control system

Abstract

The utility model discloses a kind of Zigbee factory environment data acquisition control systems.The utility model includes lithium battery, power module, main control module, lithium battery, Zigbee module, power control module, LED indicator light module and watchdog timer.Through selecting ultra-low power consumption MCU and high-efficiency power management chip, and introducing power control module to each functional unit is powered in time, significantly reduce the system average power consumption, suitable for long time battery power supply application.Main control module can be according to sensor acquisition cycle and Zigbee communication strategy, dynamically dispatch module operating state, combine sleep mechanism to reduce invalid power consumption, realize on-demand work.System integrated hardware watchdog, in abnormal condition, it can be automatically reset and resume operation, enhance the self-recovery ability of system, improve the long-term operation reliability of equipment in complex industrial environment.

Description

Technical Field

[0001] This utility model belongs to the field of Internet of Things (IoT) technology and relates to a Zigbee factory environment data acquisition and control system. Background Technology

[0002] With the widespread application of industrial automation and IoT technologies, factory environmental monitoring systems are gradually developing towards wireless and intelligent directions. Among these, Zigbee-based wireless data acquisition terminals are widely used in industrial settings due to their flexible networking and stable transmission capabilities. However, existing Zigbee data acquisition terminal systems still have several control-related issues, mainly in the following aspects:

[0003] 1. Inadequate energy consumption control and low power management integration: Traditional systems mostly use fixed power supply methods, and sensors and wireless communication modules work with power on for a long time. They cannot flexibly switch power supply strategies according to task status, resulting in high overall system power consumption, which is not conducive to long-term operation in battery-powered scenarios.

[0004] 2. Insufficient operational reliability: Severe electromagnetic interference in industrial settings may cause system failures due to program malfunctions or equipment interference during long-term operation. Most existing devices lack effective hardware self-recovery mechanisms, increasing manual maintenance costs.

[0005] Therefore, a Zigbee factory environment data acquisition and control system with efficient power management capabilities, low power consumption operation strategy, and high reliability operation guarantee is needed to meet the long-term, stable, and low-maintenance cost requirements of industrial sites. Summary of the Invention

[0006] The purpose of this invention is to solve the problems existing in the prior art by proposing a Zigbee factory environmental data acquisition and control system.

[0007] This utility model includes a lithium battery, a power module, a main control module, a lithium battery, a Zigbee module, a power control module, an LED indicator module, and a watchdog timer. The power module, Zigbee module, power control module, LED indicator module, and watchdog timer are all electrically connected to the main control module.

[0008] The lithium battery serves as the energy source for the entire system. The power module includes a voltage acquisition module and a power conversion module, used to convert the lithium battery input voltage to the system voltage of 3.3V to power the other modules. The main control module (MCU) is responsible for controlling the overall operation of the system, handling data acquisition, peripheral control, and inter-module communication. The Zigbee module provides low-power wireless data transmission for short-range communication between devices. The power control module provides controllable power to sensors connected to the main control board via the I2C bus, optimizing energy management. LED indicators are status indicators, controlled by the MCU to display different operating states, including power indication, communication status, and function setting status. A watchdog timer serves as a system safety protection mechanism, ensuring that the MCU can automatically reset in abnormal situations, preventing system crashes or program freezes.

[0009] Low-power MCUs and high-efficiency power management chips are selected to ensure the lowest overall system power consumption.

[0010] Furthermore, the sensor includes one or more of the following: a light sensor, a temperature and humidity sensor, an ultraviolet sensor, or a gas detection sensor.

[0011] Furthermore, the main control module is selected from STMicroelectronics' STM32F103RBT6 chip.

[0012] Furthermore, the power control module includes a PMOS transistor, an NPN transistor, and several resistors and capacitors, forming a switch control circuit. The MCU main control module controls the CON-TH pin level through GPIO control signals, thereby controlling the on / off state of the external sensor power supply V3.3D-TH through the power control module.

[0013] Furthermore, the power conversion module uses an LDO from Shanghai Mingda Microelectronics, specifically the MD7602R33 power conversion chip, to convert the battery voltage VBAT to 3.3V to power the other modules.

[0014] Furthermore, the voltage acquisition module includes a PMOS and several resistors and capacitors, and the MCU main control module controls the level of the CON-BAT pin through GPIO control signals.

[0015] Furthermore, the watchdog timer is a Texas Instruments monitoring and reset IC, model TPS3828-33DBVR.

[0016] Furthermore, the LED indicator includes two green-red LEDs and two green-blue LEDs, each controlled by one of the four GPIOs of the MCU. The LEDs light up when the IO output is high and turn off when it is low. It also includes two yellow LEDs that are connected to the Zigbee module, which indicate different working states of Zigbee by flashing at different frequencies.

[0017] Furthermore, the Zigbee module selected is E18-MS1PA2-IPX, a 2.4G wireless ZigBee 3.0 module from EBITE. It connects to the MCU via the TX2 and RX2 pins and transmits and receives data via UART serial communication.

[0018] Furthermore, metal shielding covers are installed on the main control module (MCU) and the power module.

[0019] The beneficial effects of this utility model include:

[0020] 1. Low power consumption design: By selecting an ultra-low power MCU and a high-efficiency power management chip, and introducing a power control module to provide time-sharing power to each functional unit, the average power consumption of the system is significantly reduced, making it suitable for long-term battery-powered applications.

[0021] 2. Control logic optimization: The main control module can dynamically schedule the module's operating status according to the sensor acquisition cycle and Zigbee communication strategy, and reduce unnecessary power consumption by combining a sleep mechanism to achieve on-demand operation.

[0022] 3. High reliability: The system integrates a hardware watchdog, which can automatically reset and resume operation in abnormal situations, enhancing the system's self-recovery capability and improving the long-term operational reliability of the equipment in complex industrial environments. Attached Figure Description

[0023] Figure 1 This is a block diagram of the overall structure of this utility model;

[0024] Figure 2 for Figure 1 Circuit diagram of the main control module;

[0025] Figure 3 for Figure 1 Circuit diagram of the power supply control module;

[0026] Figure 4 for Figure 1 Circuit diagram of the medium power conversion module;

[0027] Figure 5 for Figure 1 Medium voltage acquisition module circuit;

[0028] Figure 6 for Figure 1Hardware watchdog circuit;

[0029] Figure 7 for Figure 1 LED indicator circuit;

[0030] Figure 8 for Figure 1 The Zigbee module circuit in the middle. Detailed Implementation

[0031] The present invention will be further described below with reference to the accompanying drawings.

[0032] like Figure 1 As shown, a Zigbee factory environmental data acquisition and control system includes a lithium battery, a power module, a main control module, a lithium battery, a Zigbee module, a power control module, an LED indicator module, and a watchdog timer.

[0033] The lithium battery serves as the energy source for the entire system. The power module includes a voltage acquisition module and a power conversion module, used to convert the lithium battery input voltage to the system voltage of 3.3V to power the other modules. The main control module (MCU) is responsible for controlling the overall operation of the system, handling data acquisition, peripheral control, and inter-module communication. The Zigbee module features low-power wireless data transmission for short-range communication between devices. The power control module provides controllable power to sensors connected to the main control board via the I2C bus, optimizing energy management. Sensors are adapted to the specific scenario and can communicate via the I2C bus, including but not limited to one or more of the following: light sensors, temperature and humidity sensors, ultraviolet sensors, or gas detection sensors. LED indicators are status indicators controlled by the MCU to display different operating states, including power indication, communication status, and function setting status. A watchdog timer serves as a system safety protection mechanism, ensuring that the MCU automatically resets in abnormal situations to prevent crashes or program freezes.

[0034] It also includes a button module, which includes a switch and related electronic circuitry to receive user input signals, detect the button's state mechanically or electronically, and convert these signals into electrical signals to be transmitted to the main control module. When a button is pressed, the circuit's voltage level changes, thereby triggering the corresponding operation or function.

[0035] like Figure 2 As shown, in this embodiment, the main control module is selected from STMicroelectronics' STM32F103RBT6 chip.

[0036] like Figure 3As shown, the power control module includes a PMOS transistor, an NPN transistor, and several resistors and capacitors, which together form a switching control circuit. The MCU main control module controls the CON-TH pin level via GPIO control signals, thereby controlling the on / off state of the external sensor power supply V3.3D-TH through this module circuit. Specifically, when CON-TH is set to a high level, the collector and emitter of the transistor change from the cutoff state to the on state, thus grounding the gate of the PMOS transistor. Therefore, the V3.3D-TH of the PMOS transistor... GS (The voltage between the gate and source in a MOSFET device. It determines whether the MOSFET is turned on.) When the source-drain turn-on voltage is met, the system voltage of 3.3V can power the sensor through this switch; conversely, when CON-TH is set to a low level, the voltage will be turned off.

[0037] Low-power MCUs and high-efficiency power management chips are selected to ensure the lowest overall system power consumption.

[0038] like Figure 4 As shown, the power conversion module uses Shanghai Mingda Microelectronics' LDO, model MD7602R33, to convert the battery voltage VBAT to 3.3V, supplying power to various modules such as the MCU, Zigbee module, sensors, LED indicators, and hardware watchdog.

[0039] like Figure 5 As shown, the voltage acquisition module includes a PMOS transistor and several resistors and capacitors. The MCU main control module controls the CON-BAT pin level through GPIO control signals. Specifically, when CON-BAT is set to a low level, that is, the gate voltage of the PMOS transistor is low, the V of the PMOS transistor... GS To ensure the source and drain conduction voltages are met, resistors R38 and R40 divide the battery voltage equally (to reduce the voltage to a level that the MCU can measure). The ADC-BAT pin measures half of the battery voltage and inputs it to the MCU's ADC pin to obtain the current battery voltage value.

[0040] like Figure 6 As shown, the watchdog timer uses a TI (Texas Instruments) monitoring and reset IC, model TPS3828-33DBVR. Specifically, WDI is connected to the MCU's push-pull output I / O pin, outputting a high-level pulse of at least 100ns to the IC every 1.6 seconds (i.e., feeding the watchdog). If the system fails and the watchdog is not fed on time, the IC will output a low-level pulse to the RESET pin to reset the MCU (RESET is the MCU's reset button pin).

[0041] like Figure 7As shown, the green and red LEDs 3 and 4, and the green and blue LEDs 1 and 2 are each controlled by one of the MCU's four GPIOs. The LEDs light up when the IO outputs a high level and turn off when it's low. The yellow LEDs NWK_LED and RUN_LED are connected to the corresponding pins of the Zigbee module. A low-level output lights the LEDs, and different flashing frequencies indicate different Zigbee operating states: a fast flashing RUN_LED (10Hz) indicates joining or creating a network, a slow flashing RUN_LED (2Hz) indicates the module has successfully joined or created a network, and a constantly lit NWK_LED indicates an existing network.

[0042] like Figure 8 As shown, the Zigbee module selected is E18-MS1PA2-IPX, a 2.4G wireless ZigBee 3.0 module from EBITE. The module is connected to the MCU via the TX2 and RX2 pins, and transmits and receives data via UART serial communication.

[0043] Meanwhile, to prevent electromagnetic waves from the external environment from interfering with sensitive circuits such as the main control module and power supply module, metal shielding covers are installed on the main control module MCU and the power supply module. The metal shielding covers are made of a highly conductive metal material (aluminum alloy is used in this embodiment), and to ensure that its structure is as intact as possible and to reduce gaps, the metal shielding covers are manufactured using a one-piece molding technology.

[0044] The work process is as follows:

[0045] When a Zigbee module is first added to a network or when the network is started, an "Energy Detection Scan" is performed to measure the background noise level on all available Zigbee channels (such as channels 11 to 26 as defined in IEEE 802.15.4). The host computer analyzes the scan results and selects the channel with the lowest energy (i.e., the "cleanest") as the preferred communication channel.

[0046] By actively selecting and adapting to the channel environment, co-channel interference is effectively avoided, the probability of data collision is reduced, the immediacy and reliability of data transmission are improved, and the robust operation of the Zigbee network in a high-interference environment is ensured.

[0047] The MCU main control module implements timed data acquisition through its built-in timer. The non-acquisition period constitutes the largest portion of its operating cycle; therefore, optimizing power consumption during the non-acquisition phase can effectively reduce overall power consumption. During the non-acquisition period, the system automatically enters an ultra-low power standby mode, retaining only necessary low-power tasks to reduce energy consumption. Specifically:

[0048] By modifying the built-in timer configuration of the MCU main control module and adjusting the sampling frequency, unnecessary power consumption is reduced. The operation of the Zigbee wireless communication module is optimized; during non-sampling periods, the Zigbee module is configured by the MCU to enter a deep sleep mode. In this mode, the Zigbee chip retains only a small amount of register data and shuts down the power supply to the internal RF module, thereby reducing standby power consumption. When the current communication channel signal quality is detected to be good, the transmit power of the RF module is reduced, thereby reducing power consumption during data transmission.

[0049] The host computer sends the specified acquisition mode to the MCU module via Zigbee communication: high-frequency acquisition mode is suitable for critical monitoring points requiring rapid response, but consumes more power; low-frequency acquisition mode is suitable for environmental data with slower changes and can effectively reduce power consumption. The acquisition frequency can be remotely configured via Zigbee wireless communication, allowing for dynamic adjustment of the acquisition strategy according to different application scenarios. For example, it can be linked with factory equipment; the acquisition frequency can be increased during production and decreased during non-production phases to optimize energy consumption.

[0050] By shutting down or reducing power supply to peripherals during non-data acquisition periods, the system only activates during acquisition; and it supports adjusting the acquisition frequency as needed, reducing unnecessary energy consumption. For example, when data changes are minimal, reducing the acquisition frequency can effectively extend the device's battery life. It adopts the Zigbee wireless communication protocol, designed specifically for low-power, low-data-rate wireless sensor networks, suitable for applications such as remote monitoring and smart industrial equipment. The Zigbee module employs a short-time wake-up and long-time sleep mode. When the device is not in a communication state, it automatically enters sleep mode, consuming less than 5 µA, significantly reducing the overall system energy consumption. Furthermore, in field deployment, optimizing the Zigbee network topology and adding Zigbee routing nodes can ensure optimal data transmission paths, reduce communication energy consumption, and improve network stability.

[0051] Finally, it should be emphasized that the above description represents only the author's optimal design scheme for this utility model and is not intended to limit the utility model. Those skilled in the art can make improvements and enhancements without departing from the design principles of this utility model, and such modifications should be included within the protection scope of this utility model.

Claims

1. A Zigbee factory environment data acquisition control system, characterized in that: It includes a lithium battery, a power module, a main control module, a lithium battery, a Zigbee module, a power control module, an LED indicator module, and a watchdog timer; the power module, Zigbee module, power control module, LED indicator module, and watchdog timer are all electrically connected to the main control module; The lithium battery serves as the energy source for the entire system. The power module includes a voltage acquisition module and a power conversion module, used to convert the lithium battery input voltage to the system voltage of 3.3V to power the other modules. The main control module (MCU) is responsible for controlling the overall operation of the system, used for data acquisition, peripheral control, and inter-module communication. The Zigbee module has low-power wireless data transmission capabilities for short-range communication between devices. The power control module provides controllable power to sensors connected to the main control board via the I2C bus, optimizing energy consumption management. LED indicators are status indicators, controlled by the MCU to display different operating states, including power indication, communication status, and function setting status. The watchdog timer serves as a system safety protection mechanism, ensuring that the MCU can automatically reset in abnormal situations to prevent system crashes or program freezes. Low-power MCUs and high-efficiency power management chips are selected to ensure the lowest overall system power consumption.

2. The Zigbee plant environment data collection control system of claim 1, wherein: The sensor includes one or more of the following: a light sensor, a temperature and humidity sensor, an ultraviolet sensor, or a gas detection sensor.

3. The Zigbee plant environment data collection control system of claim 1, wherein: The main control module is an STM32F103RBT6 chip from STMicroelectronics.

4. The Zigbee plant environment data collection control system of claim 1, wherein: The power control module includes a PMOS transistor, an NPN transistor, and several resistors and capacitors, forming a switch control circuit. The MCU main control module controls the level of the CON-TH pin through the GPIO control signal, thereby controlling the on / off state of the external sensor power supply V3.3D-TH through the power control module.

5. The Zigbee plant environment data collection control system of claim 1, wherein: The power conversion module uses an LDO from Shanghai Mingda Microelectronics, specifically the MD7602R33 power conversion chip, to convert the battery voltage VBAT to 3.3V to power the other modules.

6. The Zigbee factory environmental data acquisition and control system as described in claim 1, characterized in that: The voltage acquisition module includes a PMOS and several resistors and capacitors. The MCU main control module controls the level of the CON-BAT pin through GPIO control signals.

7. The Zigbee factory environmental data acquisition and control system as described in claim 1, characterized in that: The watchdog timer mentioned is a monitoring and reset IC from Texas Instruments, model TPS3828-33DBVR.

8. The Zigbee factory environmental data acquisition and control system as described in claim 1, characterized in that: The LED indicator includes two green-red LEDs and two green-blue LEDs, each controlled by one of the four GPIOs of the MCU. The LEDs light up when the IO output is high and turn off when it is low. It also includes two yellow LEDs that are connected to the Zigbee module and indicate different Zigbee working states by flashing at different frequencies.

9. The Zigbee factory environmental data acquisition and control system as described in claim 1, characterized in that: Zigbee The module uses E18-MS1PA2-IPX, a 2.4G wireless ZigBee 3.0 module from EBITE. It is connected to the MCU via the TX2 and RX2 pins and transmits and receives data via UART serial communication.

10. The Zigbee factory environmental data acquisition and control system as described in claim 1, characterized in that: Metal shielding covers are installed on the main control module (MCU) and the power supply module.

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