High-reliability slot photoelectric switch with redundancy output

Abstract

The utility model provides a kind of high reliability slot photoelectric switch of redundancy output, including circuit module, and circuit module is fixed on lampshade by hot riveting;Lampshade is detachably fixedly connected in shell;Rear cover, and rear cover is detachably fixedly connected on shell;Insulated cable, and the insulated cable is inserted into shell by rear cover, and is welded with circuit module;The utility model is through the design of 4 groups of independent photoelectric detection circuit's redundancy output, integrated multiple protection function's whole circuit protection and IP67 grade sealed shockproof physical structure, solved the problems, such as traditional photoelectric switch insufficient reliability, poor environmental adaptability, low maintenance efficiency, can be widely applied in the field needing multiple work.

Description

Technical Field

[0001] This utility model belongs to the field of electrical automation, and specifically relates to a high-reliability slot-type photoelectric switch with redundant output. Background Technology

[0002] A photoelectric switch, also known as a photoelectric sensor or a contactless position switch, is a position switch that operates without mechanical contact with moving parts. The slot-type photoelectric switch is a type of through-beam photoelectric switch, where the transmitter and receiver are integrated and detected within a slot. It detects the position of opaque objects by receiving and converting infrared light between the transmitter and receiver. Slot-type photoelectric switches have advantages such as small size, high precision, and fast response speed, and are widely used.

[0003] Currently, conventional photoelectric switches only have single-redundancy detection function, and in order to reduce size and simplify circuit design, they lack protection functions and are mostly not waterproof, resulting in low reliability and greatly limiting the application range of photoelectric switches.

[0004] Chinese patent CN102983848B discloses a switching type photoelectric switch with a slotted beam pattern. Its core feature is the use of two pairs of infrared LEDs that switch between operating modes. In edge or end-of-travel position detection scenarios, such as elevator leveling detection, when the infrared light is blocked, the pair of working infrared LEDs stops and switches to the other pair; when not blocked, it remains in its original state, and when blocked again, it switches back to the previous pair. This design improves the lifespan of the transmitting tube through switching functionality, achieves a wide voltage regulation range using various voltage regulation and protection circuits, and uses a square wave generator to drive the infrared transmitting module. The received signal is processed by dynamic AC coupling and then sent to the control output circuit, providing a certain degree of anti-interference capability. However, this invention has the following drawbacks: 1) Redundancy is achieved by switching between only two pairs of infrared tubes. In scenarios with high reliability requirements, a single channel failure may cause safety hazards; 2) Relying on dynamic AC coupling circuits and square wave signals for anti-interference, false triggering or missed detection may occur in complex industrial environments; 3) It only provides a single detection signal output and lacks multi-channel independent output or composite functions, making it unsuitable for systems requiring multiple redundancy judgments or status monitoring; 4) It does not integrate self-diagnostic circuits or status feedback interfaces, making it impossible to monitor internal parameters such as infrared tube lifespan and power supply stability in real time. When a fault occurs, manual troubleshooting of each component is required, resulting in low maintenance efficiency and potentially prolonged equipment downtime. Utility Model Content

[0005] To solve the above-mentioned technical problems, this utility model provides a high-reliability slot-type photoelectric switch with redundant output.

[0006] This utility model is achieved through the following technical solution.

[0007] This utility model provides a high-reliability slot-type photoelectric switch with redundant output, comprising:

[0008] The circuit module is fixed to the lampshade by thermal riveting;

[0009] A lampshade, wherein the lampshade is detachably and fixedly connected to the housing;

[0010] The rear cover is detachably and securely attached to the outer casing;

[0011] An insulated cable is inserted into the housing through the rear cover and soldered to the circuit module.

[0012] The circuit module includes four sets of redundancy circuits mounted on a printed circuit board (PCB). Each set of redundancy circuits consists of a protection circuit, a detection circuit, an indicator light circuit, a filter circuit, and a dedicated integrated chip U1 for photoelectric sensors. The dedicated integrated chip U1 for photoelectric sensors is connected to the protection circuit, the detection circuit, the indicator light circuit, and the filter circuit. The filter circuit is also connected to the protection circuit and the detection circuit. The protection circuit is also connected to a power supply terminal.

[0013] The cross-section of the lampshade is a groove structure. The detection circuit of each set of redundancy circuits is set on both sides of the groove. The protection circuit, indicator circuit, filter circuit and photoelectric sensor dedicated integrated chip U1 in each set of redundancy circuits are set at the bottom of the groove.

[0014] The protection circuit includes a resistor R1, a Schottky diode D1, a transient voltage suppressor diode D2, and a transient voltage suppressor diode D3. One end of the resistor R1 is connected to pin 6 of the photoelectric sensor integrated chip U1 and the cathode of the transient voltage suppressor diode D2, and the other end is connected to the positive input terminal of the power supply. The cathode of the Schottky diode D1 is connected to the negative input terminal of the power supply, and its anode is connected to the anodes of the transient voltage suppressor diodes D2 and D3, and pin 2 of the photoelectric sensor integrated chip U1, and then grounded. The cathode of the transient voltage suppressor diode D3 is connected to pin 3 of the photoelectric sensor integrated chip U1.

[0015] The detection circuit includes an infrared emitting tube FS1 and an infrared receiving tube JS1; the anode of the infrared emitting tube FS1 is connected to pin 5 of the photoelectric sensor dedicated integrated chip U1, and the cathode is connected to pin 2 of the photoelectric sensor dedicated integrated chip U1; the cathode of the infrared receiving tube JS1 is connected to pin 8 of the photoelectric sensor dedicated integrated chip U1, and the anode is connected to pin 2 of the photoelectric sensor dedicated integrated chip U1.

[0016] The indicator circuit includes a light-emitting diode LED1 and a resistor R2. The anode of the light-emitting diode LED1 is connected to pin 6 of the dedicated integrated chip U1 for photoelectric sensors, and the cathode is connected to pin 1 of the dedicated integrated chip U1 for photoelectric sensors. One end of the resistor R2 is connected to pin 7 of the dedicated integrated chip U1 for photoelectric sensors, and the other end is connected to pin 2 of the dedicated integrated chip U1 for photoelectric sensors.

[0017] The filtering circuit includes capacitors C1 and C2; one end of capacitor C1 is connected to one end of resistor R1 and pin 6 of the dedicated integrated chip U1 for photoelectric sensors, and the other end is connected to the anode of Schottky diode D1; one end of capacitor C2 is connected to pin 8 of the dedicated integrated chip U1 for photoelectric sensors, and the other end is connected to the anode of infrared receiver JS1 and the cathode of infrared emitter FS1.

[0018] The lampshade and the outer shell are slidably detachable and fitted together through a limiting groove structure.

[0019] The back cover and the outer shell are detachably and fixedly connected by a snap-fit ​​structure.

[0020] The rear cover is provided with a wire hole. After the insulated cable passes through the wire hole, its end is electrically connected to the solder terminal on the circuit module by soldering.

[0021] The back cover is provided with a glue injection hole. Epoxy resin glue is injected into the glue injection hole to achieve sealing and fixation between the internal components of the outer shell and the back cover.

[0022] The dedicated integrated chip U1 for the photoelectric sensor is model DC205.

[0023] The insulated cable is a 12-core special transmission cable with a model and specification of WFTFPV2 / 12×0.15.

[0024] The beneficial effects of this utility model are as follows:

[0025] 1) The switch has 4 built-in power supply and output circuits that are completely independent, packaged as one piece and sharing a U-shaped slot for detection; when a single circuit fails, the other 3 circuits can still work normally, ensuring the continuous operation of the system or the whole machine; at the same time, the integrated design reduces the size and balances reliability and space utilization.

[0026] 2) All 4 redundant output circuits are equipped with current limiting protection, reverse polarity protection, overcurrent protection and surge protection functions, which can cope with complex environments such as power fluctuations and electromagnetic interference, and improve the stability and reliability of the switch in different scenarios.

[0027] 3) The switch is assembled with a black translucent outer shell, a translucent lampshade, and a black back cover. The interior is sealed with epoxy resin to form a sealed structure, giving the switch an IP67 dustproof, waterproof, and shockproof rating. It is suitable for harsh working conditions and extends its service life.

[0028] This invention solves the problems of insufficient reliability, poor environmental adaptability, and low maintenance efficiency of traditional photoelectric switches by setting up a redundant output design with 4 independent photoelectric detection circuits, full circuit protection with integrated multiple protection functions, and a physical structure with IP67-level sealing and shock resistance. It can be widely used in fields that require multiple functions. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of this utility model;

[0030] Figure 2 The PCB layout of the four sets of redundancy circuits of this utility model;

[0031] Figure 3 This is a schematic diagram of the principle of this utility model;

[0032] Figure 4 This is a circuit diagram of each set of redundancy circuits in this utility model;

[0033] Figure 5 For the present utility model Figure 1 Enlarged view of part A;

[0034] Figure 6 For the present utility model Figure 1 Enlarged view of part B;

[0035] In the diagram: 1-Circuit module, 2-Lamp cover, 3-Housing shell, 4-Back cover, 5-Insulated cable, 6-Limit block, 7-Mounting hole. Detailed Implementation

[0036] The technical solution of this utility model is further described below, but the scope of protection is not limited to what is described.

[0037] like Figure 1 The diagram shown is a structural schematic of this utility model. (Refer to...) Figure 5 and Figure 6 A high-reliability slot-type photoelectric switch with redundant output, comprising:

[0038] Circuit module 1 is fixed to the lampshade 2 by thermal riveting. Circuit module 1 includes four sets of redundancy circuits mounted on a printed circuit board (PCB). Each set of redundancy circuits consists of a protection circuit, a detection circuit, an indicator light circuit, a filter circuit, and a dedicated integrated chip U1 for photoelectric sensors. This redundant output design with four independent photoelectric detection circuits greatly improves the reliability of the photoelectric switch. Even if one set of circuits fails, the others can still work normally, solving the problem of insufficient reliability of traditional photoelectric switches. The PCB also has four mounting holes for connection with four corresponding posts on the lampshade 2.

[0039] The lampshade 2 is detachably and fixedly connected to the housing 3. The lampshade 2 has a groove structure in cross-section. The detection circuits for each set of redundancy circuits are located on the two side walls of the groove, while the circuit components of each set of redundancy circuits—including the protection circuit, indicator light circuit, filter circuit, and the dedicated integrated chip U1 for the photoelectric sensor—are located at the bottom of the groove. This layout facilitates the rational distribution of circuits and signal detection. Furthermore, the lampshade 2 and the housing 3 are slidably and detachably connected via a limiting groove structure. The housing 3 has a limiting groove, and the lampshade 2 has a limiting protrusion that matches the limiting groove. The limiting protrusion embeds into the limiting groove, enabling the lampshade 2 and the housing 3 to slide and detachably connect, facilitating disassembly and maintenance. The lampshade 2 is made of polycarbonate (PC) plastic, which has good mechanical and optical properties.

[0040] The rear cover 4 is detachably and fixedly connected to the outer shell 3. The rear cover 4 and the outer shell 3 are detachably and fixedly connected via a snap-fit ​​structure. The outer shell 3 has outwardly extending hooks on its edge, and the rear cover 4 has corresponding slots. The hooks engage with the slots to achieve the detachable and fixed connection between the rear cover 4 and the outer shell 3, facilitating the inspection and replacement of internal components. The rear cover 4 has a wire hole. After the insulated cable 5 passes through the wire hole, its end is electrically connected to the soldering terminal on the circuit module 1 via soldering. The rear cover 4 also has an injection hole. By injecting epoxy resin into the injection hole, the internal components of the outer shell 3 are sealed and fixed to the rear cover 4, achieving an IP67 sealing effect, providing good waterproof and dustproof capabilities, and enhancing environmental adaptability. The rear cover 4 is made of PBT plastic, which has high strength and heat resistance.

[0041] The insulated cable 5 is inserted into the outer casing 3 through the rear cover 4 and soldered to the circuit module 1. The insulated cable 5 is a 12-core special transmission cable with a model specification of WFTFPV2 / 12×0.15. Each core is marked with numbers 1 to 12 and is used for power supply and output signal transmission of 4 sets of redundant switch circuits. A limiting block 6 is integrally formed with the outer center of the rear cover 4 to realize the positioning and buffer protection of the cable, thereby improving the service life and stability of the cable.

[0042] like Figure 2 The diagram shows the PCB layout of the four sets of redundancy circuits of the utility model, combined with... Figure 3 The schematic diagram of this utility model is shown below. The circuit module 1 includes four sets of redundancy circuits mounted on a printed circuit board (PCB). Each set of redundancy circuits consists of a protection circuit, a detection circuit, an indicator light circuit, a filter circuit, and a dedicated integrated chip U1 for photoelectric sensors. The dedicated integrated chip U1 for photoelectric sensors is connected to the protection circuit, the detection circuit, the indicator light circuit, and the filter circuit. The filter circuit is also connected to the protection circuit and the detection circuit. The protection circuit also has a power supply terminal connected to it.

[0043] Furthermore, such as Figure 4 The diagram shows the circuit schematic of each set of redundancy circuits of this utility model. The protection circuit includes a resistor R1, a Schottky diode D1, a transient voltage suppression diode D2, and a transient voltage suppression diode D3. One end of the resistor R1 is connected to pin 6 of the photoelectric sensor integrated chip U1 and the cathode of the transient voltage suppression diode D2, and the other end is connected to the positive input terminal of the power supply. The cathode of the Schottky diode D1 is connected to the negative input terminal of the power supply, and its anode is connected to the anode of the transient voltage suppression diode D2, the anode of the transient voltage suppression diode D3, and pin 2 of the photoelectric sensor integrated chip U1, and then grounded. The cathode of the transient voltage suppression diode D3 is connected to pin 3 of the photoelectric sensor integrated chip U1.

[0044] Furthermore, in the protection circuit, resistor R1 and pin 6 of the dedicated integrated chip U1 for photoelectric sensors form a current-limiting protection circuit. Resistor R1 is a small power resistor to prevent excessive current from damaging the chip. Schottky diode D1 and pin 6 of the dedicated integrated chip U1 for photoelectric sensors form a reverse polarity protection circuit to avoid damage caused by reverse power supply connection. Transient voltage suppression diodes D2 and D3, respectively, form surge protection circuits with pins 6 and 3 of the dedicated integrated chip U1 for photoelectric sensors, to cope with instantaneous high voltage and high current surges. The overcurrent protection circuit is internally configured in the dedicated integrated chip U1 for photoelectric sensors. When the current at the switch output terminal exceeds a certain value and remains so for a short period of time, the overcurrent protection circuit will be triggered, causing the switch to turn off. The integration of multiple protection functions achieves full circuit protection, improving the reliability and stability of the photoelectric switch.

[0045] The detection circuit includes an infrared emitting tube FS1 and an infrared receiving tube JS1; the anode of the infrared emitting tube FS1 is connected to pin 5 of the photoelectric sensor dedicated integrated chip U1, and the cathode is connected to pin 2 of the photoelectric sensor dedicated integrated chip U1; the cathode of the infrared receiving tube JS1 is connected to pin 8 of the photoelectric sensor dedicated integrated chip U1, and the anode is connected to pin 2 of the photoelectric sensor dedicated integrated chip U1.

[0046] Furthermore, the infrared emitting tube FS1 and the 5th pin of the photoelectric sensor dedicated integrated chip U1 form a transmitting circuit, and the photoelectric sensor dedicated integrated chip U1 emits a constant current to drive the infrared emitting tube to emit light; the infrared receiving tube JS1 and the 5th pin of the photoelectric sensor dedicated integrated chip U1 form a receiving circuit, and the photoelectric sensor dedicated integrated chip U1 completes the light detection and outputs an electrical signal.

[0047] The indicator circuit includes a light-emitting diode LED1 and a resistor R2. The anode of the light-emitting diode LED1 is connected to pin 6 of the dedicated integrated chip U1 for photoelectric sensors, and the cathode is connected to pin 1 of the dedicated integrated chip U1 for photoelectric sensors. One end of the resistor R2 is connected to pin 7 of the dedicated integrated chip U1 for photoelectric sensors, and the other end is connected to pin 2 of the dedicated integrated chip U1 for photoelectric sensors.

[0048] Furthermore, LED1, together with pins 6 and 1 of the dedicated integrated chip U1 for photoelectric sensors, forms a light-emitting circuit to indicate whether light is present or blocked. Resistor R2, together with pin 7 of the dedicated integrated chip U1 for photoelectric sensors, forms a circuit. By grounding pin 7 of the dedicated integrated chip U1 for photoelectric sensors, LED1 lights up when light is present. If resistor R2 is not soldered and pin 7 of the dedicated integrated chip U1 for photoelectric sensors is left floating, LED1 lights up when light is blocked, allowing users to intuitively understand the working status.

[0049] The filtering circuit includes capacitor C1 and capacitor C2; one end of capacitor C1 is connected to one end of resistor R1 and pin 6 of the dedicated integrated chip U1 for photoelectric sensors, and the other end is connected to the anode of Schottky diode D1; one end of capacitor C2 is connected to pin 8 of the dedicated integrated chip U1 for photoelectric sensors, and the other end is connected to the anode of infrared receiver JS1 and the cathode of infrared emitter FS1.

[0050] Furthermore, capacitor C1 and pin 6 of the dedicated integrated chip U1 for photoelectric sensors form a power supply filter circuit to complete the filtering of the power supply circuit; capacitor C2 and pin 8 of the dedicated integrated chip U1 for photoelectric sensors form a detection filter circuit to complete the filtering of the detection circuit; effectively reducing interference signals in the circuit and improving the accuracy and stability of the signal.

[0051] The dedicated integrated chip U1 for the photoelectric sensor is model DC205. This chip is a domestically produced chip that integrates voltage regulation, overcurrent protection, and constant current functions required for signal indicator circuits and transmitting circuits. It can meet the requirements for miniaturization and reliability of switches, and helps to realize the domestic substitution and miniaturization design requirements of products.

[0052] The outer shell 3 is made of polycarbonate (PC) plastic and is dyed with a black dye that transmits infrared light, which ensures the transmittance of infrared light and can prevent interference from external light to a certain extent.

[0053] The beneficial effects of this utility model are as follows: Through the redundant output design of 4 sets of independent redundant circuits, combined with the full circuit protection with multiple protection functions such as integrated current limiting, reverse polarity, and surge protection, as well as the structural design of IP67-level sealing and corrosion-resistant cables, this utility model not only greatly improves reliability and environmental adaptability, but also facilitates maintenance due to the detachable connection structure, and meets the miniaturization requirements by using integrated domestic chips, effectively solving many drawbacks of traditional photoelectric switches, and can be widely used in many fields.

Claims

1. A high reliability slot photointerrupter with excess redundancy output, characterized in that, include: Circuit module (1), the circuit module (1) is fixed to the lamp cover (2) by heat riveting; The lampshade (2) is detachably and fixedly connected to the housing (3); Rear cover (4), which is detachably and fixedly connected to the outer shell (3); An insulated cable (5) is inserted into the outer casing (3) through the rear cover (4) and welded to the circuit module (2).

2. A high reliability slotted optoelectronic switch with excess degree of output as claimed in claim 1 wherein: the said optoelectronic switch is a slotted optoelectronic switch with excess degree of output. The circuit module (1) includes four sets of redundancy circuits mounted on a printed circuit board (PCB). Each set of redundancy circuits consists of a protection circuit, a detection circuit, an indicator light circuit, a filter circuit, and a dedicated integrated chip U1 for photoelectric sensors. The dedicated integrated chip U1 for photoelectric sensors is connected to the protection circuit, the detection circuit, the indicator light circuit, and the filter circuit. The filter circuit is also connected to the protection circuit and the detection circuit. The protection circuit is also connected to a power supply terminal.

3. A high reliability slotted optoelectronic switch with excess degree of output according to claim 1 or 2, characterized in that: The cross-sectional view of the lampshade (2) is a groove structure. The detection circuit of each set of redundancy circuits is set on both sides of the groove. The protection circuit, indicator circuit, filter circuit and photoelectric sensor dedicated integrated chip U1 of each set of redundancy circuits are set at the bottom of the groove.

4. A high-reliability slot-type photoelectric switch with redundant output as described in claim 2, characterized in that: The protection circuit includes a resistor R1, a Schottky diode D1, a transient voltage suppressor diode D2, and a transient voltage suppressor diode D3. One end of the resistor R1 is connected to pin 6 of the photoelectric sensor integrated chip U1 and the cathode of the transient voltage suppressor diode D2, and the other end is connected to the positive input terminal of the power supply. The cathode of the Schottky diode D1 is connected to the negative input terminal of the power supply, and its anode is connected to the anodes of the transient voltage suppressor diodes D2 and D3, and pin 2 of the photoelectric sensor integrated chip U1, and then grounded. The cathode of the transient voltage suppressor diode D3 is connected to pin 3 of the photoelectric sensor integrated chip U1. The detection circuit includes an infrared emitting tube FS1 and an infrared receiving tube JS1; the anode of the infrared emitting tube FS1 is connected to pin 5 of the photoelectric sensor dedicated integrated chip U1, and the cathode is connected to pin 2 of the photoelectric sensor dedicated integrated chip U1; the cathode of the infrared receiving tube JS1 is connected to pin 8 of the photoelectric sensor dedicated integrated chip U1, and the anode is connected to pin 2 of the photoelectric sensor dedicated integrated chip U1. The indicator circuit includes a light-emitting diode LED1 and a resistor R2. The anode of the light-emitting diode LED1 is connected to pin 6 of the dedicated integrated chip U1 for photoelectric sensors, and the cathode is connected to pin 1 of the dedicated integrated chip U1 for photoelectric sensors. One end of the resistor R2 is connected to pin 7 of the dedicated integrated chip U1 for photoelectric sensors, and the other end is connected to pin 2 of the dedicated integrated chip U1 for photoelectric sensors. The filtering circuit includes capacitors C1 and C2; one end of capacitor C1 is connected to one end of resistor R1 and pin 6 of the dedicated integrated chip U1 for photoelectric sensors, and the other end is connected to the anode of Schottky diode D1; one end of capacitor C2 is connected to pin 8 of the dedicated integrated chip U1 for photoelectric sensors, and the other end is connected to the anode of infrared receiver JS1 and the cathode of infrared emitter FS1.

5. A high-reliability slot-type photoelectric switch with redundant output as described in claim 1, characterized in that: The lampshade (2) and the outer shell (3) are slidably detachable and fit together through a limiting groove structure.

6. A high-reliability slot-type photoelectric switch with redundant output as described in claim 1, characterized in that: The rear cover (4) and the outer shell (3) are detachably and fixedly connected by a snap-fit ​​structure.

7. A high-reliability slot-type photoelectric switch with redundant output as described in claim 1, characterized in that: The rear cover (4) is provided with a wire hole. After the insulated cable (5) passes through the wire hole, its end is electrically connected to the welding terminal on the circuit module (1) by soldering.

8. A high-reliability slot-type photoelectric switch with redundant output as described in claim 1 or 7, characterized in that: The back cover (4) is provided with a glue-filling hole. By injecting epoxy resin glue into the glue-filling hole, the internal components of the outer shell (3) and the back cover (4) are sealed and fixed.

9. A high-reliability slot-type photoelectric switch with redundant output as described in claim 1, characterized in that: The dedicated integrated chip U1 for the photoelectric sensor is model DC205.

10. A high-reliability slot-type photoelectric switch with redundant output as described in claim 1, characterized in that: The insulated cable (5) is a 12-core transmission cable with a model and specification of WFTFPV2 / 12×0.15.

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