A data acquisition controller circuit

Abstract

The utility model discloses a data acquisition controller circuit, include: power module, main control core module, main control core module, photoelectric coupler isolation input module, photoelectric coupler isolation input module, output control module, running pilot lamp, output relay, storage module, communication module, the power module is used to convert external ac to 24V direct current bus, and is equipped with 0V common bus, wherein, power module, main control core module, counting inductor, running pilot lamp all parallel in the same 24V direct current bus, and 0V terminal all parallel in the same 0V common bus realizes single point grounding. The utility model is full hardware closed loop, single bus parallel power supply, and forms single point grounding system.

Description

Technical Field

[0001] This utility model relates to the field of data acquisition and control technology, and in particular to a data acquisition controller circuit. Background Technology

[0002] In fields such as industrial automation and intelligent manufacturing, data acquisition controllers serve as crucial nodes for front-end sensing and execution, and their circuit architecture directly determines the system's reliability, real-time performance, and maintainability. Existing data acquisition controller circuits have the following shortcomings: 1) The output stage is mostly relays directly driven by the main control pin, without hardware interlocking. Once the program runs away or the power is lost, the actuator (contactor, valve, etc.) will still remain in a dangerous state. 2) The whole machine has no single-point grounding design. When the 24V load changes suddenly, the ground potential drifts, which may cause AD code errors or even main control (MCU) reset. 3) Requires additional switching power supply, isolation barrier and I / O expansion unit, complex wiring inside the cabinet, and many points of failure; 4) Power loss data protection relies on large capacitors or lithium batteries, which have short lifespans and a high risk of failure at high temperatures.

[0003] Therefore, there is an urgent need for a "fully hardware closed-loop, highly reliable" data acquisition controller circuit to solve the above pain points. Utility Model Content

[0004] The purpose of this invention is to provide a data acquisition controller circuit that features a fully hardware closed loop, parallel power supply via a single bus, and a single-point grounding system.

[0005] To achieve the above objectives, the following technical solution is adopted: A data acquisition controller circuit includes: a power supply module for converting external AC power to a 24V DC bus, and a 0V common bus; a main control core module connected in parallel to the 24V DC bus, and equipped with an isolated digital input terminal K1 and a relay output terminal K2; a counting sensor plugged into the 24V DC bus and the isolated digital input terminal K1, forming a parallel power supply and pulse signal hard-wired loop; an optocoupler isolated input module placed inside the isolated digital input terminal K1, used to convert the 24V pulse from the counting sensor into a 3.3V signal; a data acquisition module, hard-wired electrically connected to the optocoupler isolated input module, used to perform charge integration sampling on the 3.3V signal; an output control module, hard-wired electrically connected to the relay output terminal K2 of the main control core module; a running indicator light for indicating the operating status of the equipment; and an output relay, with its coil side connected to the output control module and its contact side connected in series with the running indicator light and then returning to the 24V DC bus, forming an indicator light hardware loop. The storage module is hardwired and electrically connected to the data acquisition module and the main control core module to store the sampled data; the communication module is hardwired and electrically connected to the main control core module to send data to the host computer / cloud; the power module, the main control core module, the counting sensor, and the operation indicator are all connected in parallel to the same 24V DC bus, and the 0V terminals are all connected in parallel to the same 0V common bus to achieve single-point grounding.

[0006] Preferably, the counting sensor is connected between the 24V DC bus and the isolated digital input terminal K1 via a red-yellow-black three-core wire.

[0007] Preferably, the data acquisition module uses an MCP3461 ADC and is electrically connected to the main control core module via a hardwired SPI bus.

[0008] Preferably, the optocoupler isolated input module uses an EL817C optocoupler, whose input side is connected to the counting sensor, and whose output side is pulled up to 3.3V and directly electrically connected to the ADC input of the data acquisition module via hardwire.

[0009] Preferably, the storage module includes FRAM and SD card, both of which are hardwired electrically connected to the main control core module.

[0010] Preferably, the communication module uses an RS-485 interface.

[0011] Preferably, an optocoupler-isolated output module is further provided between the output control module and the output relay; the optocoupler-isolated output module adopts a TLP351 optocoupler.

[0012] By adopting the above solution, the beneficial effects of this utility model are: 1) Full hardware closed loop: The three major links of sensor power supply, pulse acquisition and operation indicator light drive are all completed through hard-wired electrical closed loop. Power-on self-test, status indication and safety interlock can be realized without software intervention. The system has a fast response speed and eliminates the risk of loss of control caused by program runaway. 2) Single busbar parallel power supply, "zero branch line" in the cabinet: 24V DC busbar and 0V common busbar run through all functional modules. Counting sensors and running indicator lights are directly plugged into the busbar, saving traditional switching power supplies, terminal blocks and most wiring. The on-site installation efficiency is high, while reducing line loss and contact oxidation failure. 3) Single-point grounding: The 0V terminals of the power module, main control core module, counting sensor, and running indicator are connected to the same 0V common bus to form a single-point grounding system, which effectively eliminates ground loops and can be directly and stably operated in strong interference environments such as substations and rail transit for a long time. 4) The storage module uses FRAM + SD card dual storage, ensuring zero data loss when power is off; 5) Dual optocoupler isolation architecture with strong anti-interference capability: The input stage converts 24V pulses to 3.3V through optocoupler isolation input modules, and the output stage isolates the main control core module signals from the output relays through optocoupler isolation output modules, which meets the requirements of densely arranged frequency converters and high-power servo drives. Attached Figure Description

[0013] Figure 1 This is a schematic block diagram of the present invention; Figure 2 This is the electrical wiring diagram for the power supply module, main control core module, and counting sensor of this utility model; Figure 3 This is the electrical wiring diagram of the main control core module and the counting sensor of this utility model; The following are explanations of the labels in the attached diagram: 1—Power supply module, 2—Main control core module 3—Counting sensor, 4—Optically isolated input module, 5—Data acquisition module, 6—Output control module 7—Run indicator light, 8—Output relay 9—Storage module, 10—Communication module 11—Optically isolated output module. Detailed Implementation

[0014] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, not the entire structure.

[0015] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0016] In the description of this embodiment, the terms "upper," "lower," "left," and "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, 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, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0017] Reference Figures 1 to 3 As shown, this utility model provides a data acquisition controller circuit, including: Power module 1: Power module 1 is used to convert external AC power to a 24V DC bus M1, and has a 0V common bus M2; power module 1 includes a step-down unit, which is implemented using L02-60P, to reduce the voltage to 24V.

[0018] Main control core module 2: The main control core module 2 is connected in parallel to the 24V DC bus M1 and is equipped with an isolated digital input terminal K1 and a relay output terminal K2. Main control core module 2 uses an L02S-32MT (32-bit Cortex-M0, 48MHz). The on-chip Flash memory only stores the communication protocol and self-describing file and does not participate in real-time control. All I / O ports are mapped to hard-wired through registers, with high impedance by default upon power-on to ensure a safe state even with "zero software". Main control core module 2 has built-in RS-485 transceiver enable pins DE and RE, which are hard-wired electrically connected to communication module 10 to achieve automatic direction switching.

[0019] Counting sensor 3: The counting sensor 3 is plugged into the 24V DC bus M1 and the isolated digital input terminal K1, forming a parallel power supply and pulse signal hard-wired loop; the counting sensor 3 is plugged into the 24V DC bus M1 and the isolated digital input terminal K1 via a red-yellow-black three-core wire. Furthermore, the counting sensor 3 is an NPN normally open photoelectric / proximity switch.

[0020] Please continue to refer to Figure 3 This serves as the "power supply + pulse signal" connection between the counting sensor 3 and the main control core module 2. The counting sensor 3 is connected to the main control core module 2 via a red-yellow-black three-core wire. The red-yellow-black three-core wire consists of: red wire → DC bus M1 (24V); yellow wire → isolated digital input terminal K1; and black wire → common bus M2 (0V), forming an integrated hard-wired circuit for "parallel power supply + pulse signal". This eliminates the need for an external switching power supply and isolation barrier, and the wiring length can reach 100m. The red wire is the 24V positive terminal of the counting sensor 3, connected to... Figure 2 The DC bus M1 (24V) is connected to the counter sensor 3; the yellow wire is the pulse output of the counter sensor 3 (NPN pull-down); the black wire is the 0V of the counter sensor 3. Figure 2 The common bus M2 (0V) in the system.

[0021] Figure 2 The circuit disclosed in the paper is used as a "distribution panel". Figure 3 The circuit disclosed in the paper, consisting of "electrical equipment + feedback signal line", forms a complete hardware closed loop of sensor power supply - pulse acquisition - indicator light drive.

[0022] Data acquisition module 5: The data acquisition module 5 is hardwired and electrically connected to the optocoupler isolated input module 4, and is used to perform charge integration sampling on the 3.3V signal; the data acquisition module 5 adopts an MCP3461 ADC and is hardwired and electrically connected to the main control core module 2 via the SPI bus.

[0023] The data acquisition module 5 uses an MCP3461 ADC as its core component. Its configuration registers are electrically connected to the main control module 2 via a hardwired SPI bus (SCK, SDI, SDO, CS). The sampling rate is programmable from 1.8kbps to 16ksps. This embodiment uses 3.6ksps with a 200μs charge integration window, capable of completely capturing even narrow 5μs pulses.

[0024] Optical isolation input module 4: Optocoupler isolated input module 4, located inside isolated digital input terminal K1, is used to convert the 24V pulse of counter sensor 3 into a 3.3V signal. The optocoupler isolated input module 4 adopts EL817C optocoupler, whose input side is connected to counter sensor 3, and whose output side is pulled up to 3.3V and directly electrically connected to the ADC input of data acquisition module 5 by hardwire.

[0025] The optocoupler-isolated input module 4, located inside the isolated digital input terminal K1, uses an EL817C optocoupler (CTR≥300%, isolation withstand voltage 5kV). The 24V pulse sent by the counting sensor 3 is optocoupled into a 3.3V signal by the optocoupler-isolated input module 4. The input-side current-limiting resistor is 2.2kΩ / 0.5W, which can withstand 24V±20% fluctuation; the output-side pull-up resistor is 3.3V / 1kΩ, which is directly hardwired and electrically connected to the ADC input pin of the data acquisition module 5, with a signal delay ≤2μs, ensuring no loss during high-speed counting at 20kHz.

[0026] Output control module 6: The output control module 6 is electrically connected by hard wire to the relay output terminal K2 of the main control core module 2.

[0027] Operation indicator light 7: The operation indicator light 7 uses an 8mm metal-cased LED light with a built-in 6.8kΩ / 1W current-limiting resistor. It is directly connected in parallel to the 24V DC bus M1, with a brightness ≥100cd and a viewing angle of 180°, meeting the visibility requirements in industrial high-light environments. It is used to display the operating status of the equipment. The on / off state of the indicator light circuit is controlled solely by the hardware contact of the relay output terminal K2.

[0028] Output relay 8: Output relay 8 has its coil side connected to output control module 6, and its contact side connected in series with running indicator light 7 before returning to the 24V DC bus M1, forming a hardware circuit for the indicator light. An optocoupler-isolated output module 11 is also provided between output control module 6 and output relay 8; the optocoupler-isolated output module 11 uses a TLP351 optocoupler. The output control module 6 and output relay 8 are isolated using a TLP351 optocoupler (IGBT drive optocoupler, isolation withstand voltage 2.5kV, common-mode rejection 35kV / μs). Output relay 8 controls external devices (such as motors and solenoid valves) and indicates the operating status of the devices through running indicator light 7.

[0029] Storage module 9: The storage module 9 is hardwired and electrically connected to the data acquisition module 5 and the main control core module 2, and is used to store the sampled data. Furthermore, the storage module 9 includes an FRAM and an SD card, both of which are hardwired and electrically connected to the main control core module 2.

[0030] The FRAM in storage module 9 uses Fujitsu MB85RC256V (256kbit, I²C interface, 10^14 erase / write cycles). The SD card uses a self-ejecting Micro-SD socket, which is electrically connected to the main control core module 2 via SPI bus, supports FAT32 file system, and has a maximum size of 32GB.

[0031] Communication Module 10: The communication module 10 is hardwired and electrically connected to the main control core module 2, and is used to send data to the host computer / cloud. Furthermore, the communication module 10 uses an RS-485 interface.

[0032] Among them, the power supply module 1, the main control core module 2, the counting sensor 3, and the running indicator light 7 are all connected in parallel to the same 24V DC bus M1, and the 0V terminals are all connected in parallel to the same 0V common bus M2 to achieve single-point grounding.

[0033] Input chain: Counting sensor 3 → Optocoupler-isolated input module 4 → Data acquisition module 5 → Main control core module 2; Output chain: Main control core module 2 → Output control module 6 → Optocoupler-isolated output module 11 → Output relay 8 → Running indicator light 7. In the output chain, output control module 6 is a low-voltage control circuit, and output relay 8 is a high-voltage / high-current actuator. Because output control module 6 and output relay 8 are set up independently, when output relay 8 is damaged, only the entire module needs to be replaced without affecting output control module 6, facilitating maintenance and expansion.

[0034] This utility model provides a data acquisition controller circuit, which is mounted on a 35mm DIN rail. All functional modules are arranged from left to right as follows: power module 1, main control core module 2, data acquisition module 5, storage module 9, communication module 10, and output control module 6. The 24V DC bus M1 and the 0V common bus M2 are mounted on the edge of the PCB of the power module 1, extending outwards as 2.5mm pluggable terminals, forming a "common electrical backbone" on the 35mm DIN rail. Pluggable terminals are located at the bottom of the module, mechanically engaging with the 24V DC bus M1 and the 0V common bus M2 respectively, achieving parallel power supply via "zero branch lines." Buses M1 and M2 run through the entire rail.

[0035] The workflow of this utility model is as follows: 1) Power-on phase: When an external AC220V input is made, power module 1 establishes a 24V DC bus M1 within 200ms. If the voltage is greater than 21.6V and overload detection is not triggered, the main control core module 2 releases the hardware interlock, and the system enters standby mode; 2) Counting stage: When the counting sensor 3 detects the target, the yellow line outputs an NPN pull-down pulse, which is then isolated by the optocoupler isolation input module 4 and converted into a 3.3V square wave, which directly enters the data acquisition module 5; 3) Output stage: When the count value reaches the preset threshold of the host computer, the main control core module 2 pulls down the corresponding pin, the TLP351 optocoupler is turned on → the coil of the output relay 8 is energized → the normally open contact is closed → the running indicator 7 is lit. The entire link is completed in pure hardware with a delay of ≤5ms. 4) Power failure protection stage: If the power grid drops momentarily and the bus voltage is <21.6V, the power module 1 will trigger hardware interlock within 1ms. The TLP351 optocoupler will be immediately cut off → the output relay 8 coil will be de-energized → the actuator will be safely disconnected, the running indicator 7 will be turned off synchronously, and the FRAM will save the last state before the power failure and will be automatically uploaded after power is restored.

[0036] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model. Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the utility model and are not intended to limit the implementation of this utility model. For those skilled in the art, various obvious changes, readjustments, and substitutions can be made without departing from the protection scope of this utility model. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A data acquisition controller circuit, characterized in that, include: The power module is used to convert external AC power to a 24V DC bus, and also has a 0V common bus. The main control core module is connected in parallel to the 24V DC bus and is equipped with an isolated digital input terminal K1 and a relay output terminal K2; The counting sensor is plugged between the 24V DC bus and the isolated digital input terminal K1 to form a parallel power supply and pulse signal hard-wired circuit. The optocoupler isolated input module, located inside the isolated digital input terminal K1, is used to convert the 24V pulse of the counting sensor into a 3.3V signal; The data acquisition module is hardwired and electrically connected to the optocoupler isolated input module, and is used to perform charge integration sampling on the 3.3V signal; The output control module is electrically connected by hard wire to the relay output terminal K2 of the main control core module; Operating indicator lights are used to indicate the operating status of the equipment; The output relay has its coil side connected to the output control module and its contact side connected in series with the running indicator light before returning to the 24V DC bus, thus forming the indicator light hardware circuit. The storage module is hardwired and electrically connected to the data acquisition module and the main control core module, and is used to store the sampled data; The communication module is electrically connected to the main control core module via hard wiring and is used to send data to the host computer / cloud. The power supply module, main control core module, counting sensor, and operation indicator are all connected in parallel to the same 24V DC bus, and the 0V terminals are all connected in parallel to the same 0V common bus to achieve single-point grounding.

2. The data acquisition controller circuit according to claim 1, characterized in that, The counting sensor is connected between the 24V DC bus and the isolated digital input terminal K1 via a red-yellow-black three-core wire.

3. The data acquisition controller circuit according to claim 1, characterized in that, The data acquisition module uses an MCP3461 ADC and is electrically connected to the main control core module via a hardwired SPI bus.

4. The data acquisition controller circuit according to claim 3, characterized in that, The optocoupler isolated input module uses an EL817C optocoupler, whose input side is connected to the counting sensor, and whose output side is pulled up to 3.3V and directly electrically connected to the ADC input of the data acquisition module via hardwire.

5. The data acquisition controller circuit according to claim 1, characterized in that, The storage module includes FRAM and SD card, both of which are hardwired and electrically connected to the main control core module.

6. The data acquisition controller circuit according to claim 1, characterized in that, The communication module uses an RS-485 interface.

7. The data acquisition controller circuit according to claim 1, characterized in that, An optocoupler isolation output module is also provided between the output control module and the output relay; the optocoupler isolation output module adopts TLP351 optocoupler.

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