A safety shutdown system for a laser controller

Abstract

The utility model discloses a safety shutdown system of laser controller, wherein, safety shutdown system of laser controller, including main control module, vice control module and safety execution module, main control module has first independent power supply, vice control module has second independent power supply, vice control module is connected with main control module communication through first isolation unit, safety execution module has third independent power supply, safety execution module is connected with main control module through second isolation unit, and is connected with vice control module through third isolation unit, safety execution module is configured as the response to receive the shutdown signal from any one of main control module or vice control module, and executes shutdown action to cut off laser output passage passage. The utility model technical scheme aims at solving the problem that the existing laser controller causes the laser to be unable to be safely shut down because of single system failure, and there is the personal safety hidden danger.

Description

Technical Field

[0001] This utility model relates to the field of laser control technology, and in particular to a safety shutdown system for a laser controller. Background Technology

[0002] With the development of laser technology, laser controllers are widely used in industrial processing, medical fields, and other areas. However, most existing laser controllers rely on a single control system to achieve laser shutdown. If the control module or actuator malfunctions, it may lead to uncontrolled laser output. As a high-energy beam, laser light can easily cause serious harm to the human body, such as burns and eye damage, posing a serious threat to the safety of operators. Utility Model Content

[0003] The main purpose of this invention is to provide a safe shutdown system for a laser controller, which aims to solve the problem that existing laser controllers cannot safely shut off the laser due to a single system failure, posing a risk to personal safety.

[0004] To achieve the above objectives, the laser controller safety shutdown system proposed in this utility model is connected to the laser output path and includes:

[0005] The main control module has a first independent power supply for generating a first laser control signal;

[0006] The secondary control module has a second independent power supply for generating a second laser control signal and is communicatively connected to the main control module through a first isolation unit.

[0007] The safety execution module has a third independent power supply and is connected to the main control module and the sub-control module through a second isolation signal and a third isolation signal, respectively, for receiving a first laser control signal and a second laser control signal;

[0008] Both the main control module and the secondary control module are configured to perform self-tests upon power-on or upon receiving a start command, and to send a shutdown signal to the safety execution module if the self-test fails.

[0009] The safety execution module is configured to perform a shutdown action to cut off the laser output path in response to receiving a shutdown signal from either the main control module or the sub-control module.

[0010] In one possible implementation, the safety execution module includes a relay, a PWM output unit, and a feedback signal detection unit.

[0011] The relay is connected in series in the laser output path, and its control terminal is connected to the sub-control module, used to turn the laser output path on or off according to the second laser control signal;

[0012] The PWM output unit is connected in series in the laser output path, and its control terminal is connected to the main control module to adjust the laser power or turn off the output according to the first laser control signal.

[0013] The feedback signal detection unit is used to detect the operating status of the relay and the PWM output unit, and send the detected feedback signal to the sub-control module and / or the main control module.

[0014] In one possible implementation, the first isolation unit, the second isolation unit, and the third isolation unit include any one of a digital isolator, a magnetic isolator, and an optical coupler.

[0015] In one possible implementation, a heartbeat communication detection mechanism is provided between the main control module and the sub-control module to periodically send and receive heartbeat communication signals to each other. When the main control module or the sub-control module does not receive the other party's heartbeat communication signal within a preset time, or when the received heartbeat communication signal indicates that the other party's state is abnormal, it is determined that the self-test has failed and a shutdown signal is sent to the security execution module.

[0016] In one possible implementation, the safety execution module further includes a surge protection circuit disposed in the laser output path.

[0017] This utility model's technical solution achieves dual-system redundancy and electrical isolation by independently powering the main and auxiliary control modules and communicating through an isolation unit, thus solving the problem of laser runaway caused by single-system failure or electrical interference. Simultaneously, the main and auxiliary modules perform self-checks upon power-on and startup and send a shutdown signal upon failure. The safety execution module responds to any shutdown signal by redundantly shutting down the laser signal, enabling rapid fault detection and forced shutdown to prevent accidental laser output. Furthermore, by incorporating surge protection circuits and feedback detection, the system's anti-interference capability and status monitoring accuracy are effectively improved, ensuring safe and reliable laser control. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0019] Figure 1 This is a system schematic diagram of an embodiment of the present invention;

[0020] Figure 2 This is a system flowchart of an embodiment of the present invention.

[0021] Explanation of icon numbers:

[0022] 1. Main control module; 11. First independent power supply; 2. Secondary control module; 21. Second independent power supply; 3. Safety execution module; 31. Third independent power supply; 32. Relay; 33. PWM output unit; 34. Feedback signal detection unit; 41. First isolation unit; 42. Second isolation unit; 43. Third isolation unit; 5. Surge protection circuit.

[0023] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0025] To address the problems in the background technology, this utility model proposes a safe shutdown system for a laser controller, which is connected to the laser output path, including:

[0026] The main control module has a first independent power supply for generating a first laser control signal;

[0027] The secondary control module has a second independent power supply for generating a second laser control signal and is communicatively connected to the main control module through a first isolation unit.

[0028] The safety execution module has a third independent power supply and is connected to the main control module and the sub-control module through a second isolation signal and a third isolation signal, respectively, for receiving a first laser control signal and a second laser control signal;

[0029] Both the main control module and the secondary control module are configured to perform self-tests upon power-on or upon receiving a start command, and to send a shutdown signal to the safety execution module if the self-test fails.

[0030] The safety execution module is configured to perform a shutdown action to cut off the laser output path in response to receiving a shutdown signal from either the main control module or the sub-control module.

[0031] Combined with reference Figures 1 to 2 As shown, in this embodiment, the laser controller safety shutdown system is connected to the laser output path. Its structure includes a main control module 1, a secondary control module 2, and a safety execution module 3. Each module employs an independent power supply and isolated communication design. For details, please refer to... Figure 1The schematic diagram shows that the main control module 1 is equipped with a first independent power supply 11. Its core controller uses a SOC and peripheral drive circuits, and its main function is to generate a first laser control signal, which includes laser start / stop commands and power adjustment parameters. The first independent power supply 11 can be an isolated switching power supply, with a stable output voltage and a separate ground from other module power supplies, avoiding electrical interference that could affect the signal generation accuracy of the main control module 1. The secondary control module 2 is equipped with a second independent power supply 21, which uses an FPGA and logic control circuits to generate a second laser control signal. Its signal format matches the first laser control signal, achieving redundant control of the laser output. The secondary control module 2 establishes a communication connection with the main control module 1 through a first isolation unit 41. This first isolation unit 41 can be a digital isolator, a magnetic isolator transformer, or an optocoupler. Electrical isolation between the two is achieved through non-electrical signal transmission (such as optical signals or magnetic signals) to prevent abnormal voltage or current from being conducted to the secondary control module 2 in the event of a fault in the main control module 1. Similarly, the safety execution module 3 is equipped with a third independent power supply 31, serving as the direct control unit for the laser output path. This module is connected to the main control module 1 via the second isolation unit 42 and to the auxiliary control module 2 via the third isolation unit 43. Both the second isolation unit 42 and the third isolation unit 43 can be selected from digital isolators, magnetic isolators, transformers, or optocouplers to ensure electrical isolation between the safety execution module 3 and the two control modules. It is mainly used to receive the first and second laser control signals from the main and auxiliary control modules 2 respectively, and to control whether the laser is output based on the logic state of these two signals. In a preferred embodiment, this module includes a hardware logic circuit, such as an AND gate, configured to output an enable signal to conduct the laser output path only when both the first and second laser control signals are high (indicating output is allowed); if either signal is low (off signal), the path is immediately cut off. This system, by employing a dual redundancy system of the main and auxiliary control modules 2 and a redundant output shutdown design, combined with independent power supplies and isolated communication, ensures that the system can still perform a shutdown operation in the event of a single module failure.

[0032] In one possible implementation, the safety execution module includes a relay, a PWM output unit, and a feedback signal detection unit.

[0033] The relay is connected in series in the laser output path, and its control terminal is connected to the sub-control module, used to turn the laser output path on or off according to the second laser control signal;

[0034] The PWM output unit is connected in series in the laser output path, and its control terminal is connected to the main control module to adjust the laser power or turn off the output according to the first laser control signal.

[0035] The feedback signal detection unit is used to detect the operating status of the relay and the PWM output unit, and sends the detected feedback signal to the sub-control module and / or the main control module.

[0036] Combined with reference Figures 1 to 2 As shown, in this embodiment, relay 32k1 is connected in series in the laser power supply circuit. The coil's on / off state controls the contact's closing / opening, thus physically controlling the laser output path. When the relay 32 coil is energized, the contacts close, the laser output path is connected, and the laser can be output normally; when the coil is de-energized, the contacts open, cutting off the laser output path. This physically cuts off or connects the laser output path, ensuring reliable laser source cutoff in fault conditions. A relay 32 drive circuit composed of a transistor (Q1) and a resistor (R1) is also provided. The relay 32 drive signal output from the secondary system, after current limiting by resistor R1, controls the conduction and cutoff of transistor Q1, thereby controlling the energization and de-energization of the safety relay 32K1 coil. For example, when the secondary system outputs a high-level drive signal, the transistor Q1 is turned on after current limiting by R1, energizing the safety relay 32K1 coil and causing the contacts to close. The system includes a feedback circuit for relay 32, comprising a resistor (R4). The feedback signal from relay 32 is transmitted to the secondary system via R4 to detect the actual switching state of relay 32, essentially acting as a self-test for the first redundant off-response relay. The PWM output unit 33 is also connected in series in the laser output path, consisting of an optically isolated driver module (U4) and a resistor (R5). Resistor R5 limits current, protecting the optically isolated driver module (U4) and ensuring that the SOC-driven PWM signal from the main system can be stably transmitted to subsequent circuits, thereby outputting a PWM signal for adjusting laser power or completely shutting off the laser, thus achieving another independent output control channel.

[0037] The output signal status optical isolation detection (U5) is the core of the feedback signal detection unit 34, used to detect the operating status of the PWM output unit 33, essentially acting as a second redundant shutdown PWM output unit 33 self-test. It works in conjunction with resistor (R4) to detect the feedback signal from relay 32 and determine the switching state of relay 32. It also works in conjunction with resistor (R3) to detect the output PWM laser signal, acquiring the operating status information of the PWM output unit 33, and sending the detected feedback signal to the sub-system via the PWM feedback signal line.

[0038] In one possible implementation, the first isolation unit 41, the second isolation unit 42, and the third isolation unit 43 include any one of a digital isolator, a magnetic isolator, and an optocoupler.

[0039] In one possible implementation, a heartbeat communication detection mechanism is provided between the main control module and the sub-control module to periodically send and receive heartbeat communication signals to each other. When the main control module or the sub-control module does not receive the other party's heartbeat communication signal within a preset time, or when the received heartbeat communication signal indicates that the other party's state is abnormal, it is determined that the self-test has failed and a shutdown signal is sent to the security execution module.

[0040] refer to Figure 2 As shown in the provided flowchart, in this embodiment, the main control module 1 and the secondary control module 2 establish a bidirectional communication link through the first isolation unit 41, and use a periodic interactive method to realize heartbeat detection. The main control module 1 generates a heartbeat communication signal containing its own operating status identifier according to a preset period, and transmits it to the secondary control module 2 through the first isolation unit 41; at the same time, the secondary control module 2 generates a heartbeat communication signal containing its own status information at the same period, and transmits it back to the main control module 1 through the same isolation unit. Both are equipped with timers. When the other party's heartbeat communication signal is received, the timer is cleared and the countdown is restarted; if the timer reaches the set timeout threshold and no heartbeat communication signal is received or information different from the system requirements of its own module is received, it is determined that the other party's module is faulty or the communication link is abnormal, that is, the self-test fails. At this time, the main control module 1 and the secondary control module 2 immediately send a shutdown signal to the safety execution module 3 through their respective connected isolation units (second isolation unit 42 and Q1), triggering the PWM output unit 33 to turn off the laser signal and the redundant relay 32 to disconnect the laser output path. This addresses the safety hazard of continuous laser output caused by the inability to detect single module failures or communication interruptions in traditional laser controllers in a timely manner.

[0041] In one possible implementation, the safety execution module 3 further includes a surge protection circuit 5, which is disposed in the laser output path.

[0042] Combined with reference Figure 1 As shown, in this embodiment, the surge protection circuit 5 is connected in series in the laser output path and consists of a fuse F1 and a transient voltage suppression diode D1 (TVS). The fuse is connected in series in the PWM laser signal output circuit. When the laser output path experiences overcurrent due to lightning strikes, power transients, or load abnormalities (such as short circuits), F1 quickly melts using its thermal melting characteristics, cutting off the current in the path and preventing overcurrent damage to the downstream laser load and the PWM output circuit in the safety execution module 3, thus achieving first-level overcurrent protection. The bidirectional TVS diode is connected in parallel between the output terminal and ground. When a surge voltage is mixed into the PWM laser signal and the voltage amplitude exceeds the clamping voltage of D1, D1 instantly enters a breakdown state, dissipating the surge energy as heat and simultaneously clamping the output voltage within a safe range, thus achieving second-level overvoltage protection. This effectively prevents overvoltage / overcurrent damage to hardware caused by power grid fluctuations and electromagnetic interference.

[0043] In summary, in conjunction with reference Figure 2 As shown, the working mechanism of this system is as follows: The user sends a laser start or stop command through the command input interface. This command is transmitted to the main system via communication bus 1 and simultaneously transmitted to the sub-system via the isolation communication module. The main system performs a self-test first, interacting with the sub-system via communication buses 2 and 3 to exchange heartbeat communication signals. If the heartbeat communication is determined to be abnormal (no valid response or erroneous response received within the set period), the safety shutdown procedure is immediately triggered, shutting down the optical isolation drive module and safety relay 32, cutting off the laser output path. If the heartbeat communication is normal and the sub-system responds with a self-test pass message, the main system outputs a PWM control signal through the optical isolation drive module. After receiving the ready-to-output command, the sub-system performs a triple check in sequence: first, it checks whether the main system's heartbeat communication is normal; second, it checks whether the PWM feedback signal output by the optical isolation drive module is consistent with the main system's historical switch state control command; and finally, it checks whether the feedback signal of the safety relay 32 matches the historical switch state. When the three conditions of "normal main system heartbeat, consistent PWM feedback, and matching relay 32 status" are simultaneously met, the secondary system is determined to be in a safe state. It executes laser start-up (closing safety relay 32 and maintaining PWM output) or shutdown (disconnecting safety relay 32 and stopping PWM output) according to the user command and feeds back to the main control module via communication bus 2, allowing the main control module to output PWM through module 33. If any condition is not met, the secondary system directly sends a shutdown signal to the safety execution module 3, forcibly disconnecting safety relay 32 and shutting down PWM output, achieving a safe shutdown of the laser output path. Simultaneously, it feeds back to the main control module via communication bus 2, disallowing the main control module from outputting PWM through module 33, thus redundantly shutting down the PWM output. Furthermore, after a system failure shutdown, if the user attempts to start the laser again, both the main and secondary systems will re-execute the above self-test process. If the fault is not resolved (e.g., relay 32 is stuck, or the PWM module is abnormal), the self-test will still trigger a safe shutdown, eliminating the risk of "accidental laser output startup" from a hardware logic perspective and ensuring the safety of personnel and equipment.

[0044] In the accompanying drawings of this embodiment, the same or similar reference numerals correspond to the same or similar components. In the description of this application, it should be understood that if terms such as "upper," "lower," "left," and "right" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, they are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the accompanying drawings are only for illustrative purposes and should not be construed as limiting this patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0045] The above are merely preferred embodiments of this application and are not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A safety shutdown system for a laser controller, connected to a laser output path, characterized in that, include: The main control module has a first independent power supply for generating a first laser control signal; The secondary control module has a second independent power supply for generating a second laser control signal and is communicatively connected to the main control module through a first isolation unit. The safety execution module has a third independent power supply and is connected to the main control module and the sub-control module through a second isolation signal and a third isolation signal, respectively, for receiving a first laser control signal and a second laser control signal; Both the main control module and the secondary control module are configured to perform self-tests upon power-on or upon receiving a start command, and to send a shutdown signal to the safety execution module if the self-test fails. The safety execution module is configured to perform a shutdown action to cut off the laser output path in response to receiving a shutdown signal from either the main control module or the sub-control module.

2. The safety shutdown system for the laser controller according to claim 1, characterized in that, The safety execution module includes a relay, a PWM output unit, and a feedback signal detection unit. The relay is connected in series in the laser output path, and its control terminal is connected to the sub-control module, used to turn the laser output path on or off according to the second laser control signal; The PWM output unit is connected in series in the laser output path, and its control terminal is connected to the main control module to adjust the laser power or turn off the output according to the first laser control signal. The feedback signal detection unit is used to detect the operating status of the relay and the PWM output unit, and send the detected feedback signal to the sub-control module and / or the main control module.

3. The safety shutdown system for the laser controller according to claim 1, characterized in that, The first isolation unit, the second isolation unit, and the third isolation unit include any one of a digital isolator, a magnetic isolator, and an optical coupler.

4. The safety shutdown system for the laser controller according to claim 1, characterized in that, A heartbeat communication detection mechanism is set between the main control module and the secondary control module to periodically send and receive heartbeat communication signals to each other. When the main control module or the secondary control module does not receive the other party's heartbeat communication signal within a preset time, or when the received heartbeat communication signal indicates that the other party's state is abnormal, it is judged as a self-test failure and a shutdown signal is sent to the security execution module.

5. The safety shutdown system for a laser controller according to any one of claims 1 to 4, characterized in that, The safety execution module also includes a surge protection circuit, which is disposed in the laser output path.

Images