Photovoltaic inspection robot's shooting gateway circuit board

Abstract

The utility model provides a kind of photovoltaic inspection robot photographing gateway circuit board, including substrate;Image acquisition unit is arranged on substrate, for obtaining photovoltaic image;Main control unit is arranged on substrate, and it is connected with image acquisition unit, for carrying out defect identification to the image;Safety interlocking unit is arranged on substrate, and it is composed of main control unit, fieldbus interface and serial communication circuit connected in the interface, for sending stop command to robot through the fieldbus interface when identifying defect;And power supply unit is arranged on substrate, for converting external direct current into multistage direct current voltage and power supply to each unit above-mentioned.The gateway board uses collaborative hardware architecture, position-image linkage hardware and hierarchical power supply hardware link, realizes 4G network transmission, picture upload delay is low, data accurate correlation, position information and picture binding error rate are low.

Description

Technical Field

[0001] This utility model belongs to the field of electrical equipment, specifically relating to a hardware structure of a camera gateway board that integrates image acquisition, 4G transmission and safety interlock control, and is suitable for outdoor equipment such as photovoltaic cleaning robots and power inspection robots. Background Technology

[0002] Currently, existing image gateway boards have the following drawbacks: 1. Cumbersome environment setup: WiFi coverage is small, wired network cabling is cumbersome and can easily interfere with robot operation; 2. No position linkage mechanism: Photo naming is disconnected from robot pose, resulting in poor data correlation; 3. Lack of safety protection: No abnormal state interlock is established with the robot's main controller, leading to a high risk of device drop; 4. Excessive power consumption: The 4G module operates continuously, which is not friendly to low-power devices.

[0003] The aforementioned problems urgently need to be addressed through innovative hardware-level design to improve the energy efficiency, response speed, and long-term reliability of the image gateway board. Utility Model Content

[0004] Based on the shortcomings of the existing technology, this utility model aims to provide a photovoltaic inspection robot photo gateway circuit board that integrates image acquisition, 4G transmission and safety interlock control.

[0005] This utility model discloses a camera gateway circuit board for a photovoltaic inspection robot, comprising:

[0006] substrate;

[0007] An image acquisition unit mounted on the substrate is used to acquire photovoltaic images;

[0008] The main control unit, located on the substrate, is connected to the image acquisition unit and is used to identify defects in the image.

[0009] The safety interlock unit, which is installed on the base plate, consists of a main control unit, a fieldbus interface, and a serial communication circuit connected to the interface. It is used to send a stop command to the robot via the fieldbus interface when a defect is detected.

[0010] And a power supply unit disposed on the substrate, used to convert external DC power into multi-level DC voltage and supply power to the aforementioned units.

[0011] The beneficial effects of this utility model are:

[0012] 1. Transmission efficiency: 4G network transmission ensures low latency for uploading 1080P images; 2. Precise data association: Low error rate in binding location information with images; 3. Enhanced security: Fast response time in abnormal situations greatly reduces the risk of device drops; 4. Energy consumption control: 4G intelligent start / stop saves more power consumption per day. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall embodiment of this application.

[0014] Figure 2 This is a block diagram of the structure of the gateway board circuit in an embodiment of this application.

[0015] Figure 3 This is a block diagram illustrating the power supply working principle of an embodiment of this application.

[0016] Figure 4 This is the 4G module of this application embodiment.

[0017] Figure 5 This is the main control unit in this application embodiment.

[0018] Figure 6 This is the serial communication module in the embodiments of this application.

[0019] Figure 7 This is the camera module in this application embodiment. Detailed Implementation

[0020] To further illustrate the various embodiments, the present invention provides accompanying drawings. These drawings are part of the disclosure of the present invention and are mainly used to illustrate the embodiments, and can be used in conjunction with the relevant descriptions in the specification to explain the operating principles of the embodiments. With reference to these drawings, those skilled in the art should be able to understand other possible implementations and the advantages of the present invention. Components in the drawings are not drawn to scale, and similar component symbols are generally used to represent similar components.

[0021] This utility model provides a photovoltaic inspection robot gateway photo board for image acquisition, including a PCB substrate and a main control unit, a power supply module and a safety interlock module integrated thereon.

[0022] The main control unit is used to control the functions of other modules, including using a template matching model to identify photovoltaic panel defects in images captured by the camera, uploading images to the cloud platform server through the 4G module, and using hardware circuitry to enable on-demand start and stop of the 4G module, significantly reducing standby power consumption.

[0023] The power supply module is powered by the robot's main control board. It divides the 24V voltage into 12V, 5V, 3.85V, and 3.3V through different voltage divisions to power the camera, 4G module, Ethernet chip, and core board.

[0024] The safety interlock module consists of a main control unit, a fieldbus interface, and a serial communication circuit connected to the interface. When the model in the main control unit detects a defect in the photovoltaic panel, it sends an abnormal status to the robot's main control board through the RS485 interface, and the main control board stops the motor to ensure the robot's safety.

[0025] Furthermore, the gateway board adopts a collaborative hardware architecture, with the gigabit image link using RJ45 interface copper foil traces and impedance control of 100Ω±10%, and differential pair length difference ≤200mil. This ensures high-speed, stable, and low-latency transmission of 1080P image data from the camera to the main control unit for processing, without relying on unstable WiFi or complex wired cabling.

[0026] Furthermore, the enable pin of the 4G module power chip on the gateway board is connected in series with a 10K resistor to the GPIO output of the main control unit.

[0027] Furthermore, the RS485 communication channel of the gateway board has a 120Ω terminating resistor connected in parallel to the A / B pins of the serial-to-RS485 chip. Simultaneously, a 3.3KΩ pull-up resistor is connected to pin A, and a 3.3KΩ pull-down resistor is connected to pin B to ensure stable RS485 communication. This optimized RS485 hardware interface circuit design ensures that abnormal status signals can be transmitted quickly and reliably to the robot's main control board, triggering an emergency stop.

[0028] Furthermore, the gateway board employs a location-image storage linkage. The main control unit's serial port receives RS485 location data, writes the location data into a filename for saving, and the file naming logic is: "light + time (string, 14 characters) + location (8 characters) + .jpg". This achieves real-time binding of location information and acquired images at the main control unit hardware level.

[0029] Example:

[0030] like Figure 1 As shown in the figure, a photovoltaic inspection robot camera gateway circuit board according to an embodiment of this application includes a main control unit 20, which is directly soldered onto the gateway board 10 and powered by a camera power supply 40a. A gigabit Ethernet chip 30 is connected to the camera. The main control unit 20 uses a template matching model to identify photovoltaic panel defects in the acquired images and simultaneously drives a 4G module 50 to upload images to the cloud platform server via a 4G module power supply 40b.

[0031] like Figure 2As shown, the safety interlock module installed on the substrate consists of a main control unit, a fieldbus interface, and a serial communication circuit connected to the interface. When the model in the main control unit (using the template matching algorithm in the prior art) identifies a defect in the photovoltaic panel, the safety interlock module sends an abnormal status to the robot main control board through the RS485 interface 60, and the main control board stops the motor to ensure robot safety.

[0032] like Figure 3 As shown, the power supply module is powered by the robot's main control board, with an input voltage of 24V. This 24V is divided into two paths: one path is converted to 12V (corresponding to 40e) via a step-down circuit to power the camera; the other path is converted to 5V via a step-down circuit. This 5V is then divided into two paths: one is stepped down to 3.8V (corresponding to 40b) to power the 4G module 50, and the other is stepped down to 3.3V (corresponding to 40c) to power the Gigabit Ethernet chip 30 and the core board along with the 5V power supply, respectively. This refined multi-level power supply module in this embodiment efficiently and accurately converts a single 24V input into various voltage levels (12V, 5V, 3.85V, 3.3V) required by the device, meeting the power supply needs of different components and optimizing the power path.

[0033] like Figure 4 As shown, the 4G module in this embodiment is a Mini-PCIe standard 52-pin packaged 4G Cat-4 LTE industrial-grade communication module, supporting a single 3.3 Vaux power supply, with typical power consumption <3 W and an operating temperature of -40 ~ +85 ℃. A W_DISABLE# hardware shutdown pin (pin 20) is reserved, and its power chip enable pin 22 is connected in series with a 10K resistor to the GPIO output of the main control unit.

[0034] like Figure 5 As shown, the main control unit in this embodiment connects to a gigabit PHY via GMAC0, providing RGMII interfaces: TXD0~3, RXD0~3, TXEN / RXDV, TXCLK / RXCLK, MDC / MDIO, with the 25 MHz REFCLK originating from the same source. PHY_RST is controlled by GPIO2_D3; the MAC-PHY delay clock is calibrated by MCLKINOUT, supporting 10 / 100 / 1000 MHz adaptive clock.

[0035] like Figure 6As shown, in this embodiment, the A3+ / B3- differential lines in the serial communication module are matched with a 10Ω string and protected by a TVS converter and a fuse. UART3-TX2 / RX2 is directly connected to the transceiver DI / RO, and RE and SHDN are pulled up to VCC via a 10kΩ resistor to enable the chip to operate in self-transmit / receive mode. Simultaneously, a 3.3KΩ pull-up resistor R6 is connected to pin A, and a 3.3KΩ pull-down resistor R10 is connected to pin B to ensure stable RS485 levels in idle state.

[0036] like Figure 7 As shown, in this embodiment of the camera module, the RTL8211FD-CG gigabit PHY is connected to the MAC via RGMII, and the MDI0~3± differential pins are terminated in series via a 33Ω ohmmeter. RXCLK / RXC are from the same 25MHz source. A 2.49k pull-down pin sets PHYAD=1, REG_OUT outputs 1.0V to power the core, and DVDD33 / AVDD10 / PLL are independent LDOs with 100nF decoupling. CHV_RST is active low for reset.

[0037] Although the present invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the present invention without departing from the spirit and scope of the present invention as defined in the appended claims, and all such changes shall be within the scope of protection of the present invention.

Claims

1. A camera gateway circuit board for a photovoltaic inspection robot, characterized in that, include: substrate; An image acquisition unit mounted on the substrate is used to acquire photovoltaic images; The main control unit, located on the substrate, is connected to the image acquisition unit and is used to identify defects in the image. The safety interlock unit, which is installed on the base plate, consists of a main control unit, a fieldbus interface, and a serial communication circuit connected to the interface. It is used to send a stop command to the robot via the fieldbus interface when a defect is detected. And a power supply unit disposed on the substrate, used to convert external DC power into multi-level DC voltage and supply power to the aforementioned units.

2. The photographic gateway circuit board of a photovoltaic inspection robot according to claim 1, characterized in that, The fieldbus interface is an RS485 interface, and the serial communication circuit includes an RS485 transceiver and a 120 Ω terminating resistor connected in parallel with its A and B lines.

3. The photographic gateway circuit board of a photovoltaic inspection robot according to claim 2, characterized in that, The A line of the RS485 transceiver is connected to 3.3 V via a 3.3 kΩ pull-up resistor, and the B line is grounded via a 3.3 kΩ pull-down resistor.

4. The photographic gateway circuit board of a photovoltaic inspection robot according to claim 1, characterized in that, The serial communication circuit is a Mini-PCIe 4G module, and its power enable pin is connected to the GPIO of the main control unit through a 10 kΩ resistor.

5. The photographic gateway circuit board of a photovoltaic inspection robot according to claim 4, characterized in that, The power supply unit sequentially converts the 24V input to 12V, 5V, 3.85V and 3.3V, respectively, to power the image acquisition unit, 4G module, Ethernet chip and main control unit.

6. The photographic gateway circuit board of a photovoltaic inspection robot according to any one of claims 1 to 5, characterized in that, The substrate is equipped with an RJ45 interface for gigabit image transmission, and its differential pair trace impedance is controlled at 100 Ω ± 10%, with a length difference ≤ 200 mil.

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