A redundancy circuit for an industrial harvesting gateway

Abstract

This utility model relates to a redundant circuit for an industrial data acquisition gateway, including a main control unit powered by a three-level redundant architecture isolated power management unit. The main control unit is bidirectionally connected to a storage unit, multiple types of isolated communication and digital signal units. The isolated power management unit adopts an 'input isolation-intermediate step-down-output isolation' architecture, adaptable to a wide voltage power supply of DC 9~36V. The storage unit adopts dual redundant storage of EEPROM and FLASH. A total of 19 isolated interfaces in 5 categories, including RJ45, 2 RS485, 2 RS232, 3 digital signal inputs, and 2 digital signal outputs, are equipped with independent digital isolators and surge protectors (TVS), supporting Modbus protocol and 7 proprietary communication protocols. This utility model features full-link electrical isolation, multiple redundancies in communication links, power supply, and storage, and is suitable for high-temperature and strong electromagnetic industrial environments in the machinery industry, enabling stable data acquisition and transmission from multiple devices.

Description

Technical Field

[0001] This utility model relates to the field of industrial equipment data acquisition, and more specifically to a redundant circuit for an industrial data acquisition gateway. Background Technology

[0002] With the emergence of the smart factory concept, the primary challenge for traditional factories is how to digitally upgrade and transform existing equipment, including production data collection, data uploading, energy consumption monitoring, and automated control. This issue is particularly prominent in traditional machinery industries such as casting, forging, and heat treatment.

[0003] Traditional machinery factories face harsh working environments, complex electromagnetic conditions, diverse equipment types, and inconsistent communication interfaces and protocols. Existing data acquisition gateways are not specifically designed for the traditional machinery industry and suffer from deficiencies such as insufficient electromagnetic protection, limited communication interfaces, single communication methods, and inability to meet the communication needs of various devices. Utility Model Content

[0004] The purpose of this invention is to address the aforementioned shortcomings by proposing a redundant circuit for an industrial data acquisition gateway. This circuit can cope with the complex electromagnetic and high-temperature environments in industrial settings and has multiple types of communication interfaces. It can read and parse data from various devices and upload it to the backend system in a unified communication protocol format.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A redundant circuit for an industrial data acquisition gateway includes a main control unit powered by an isolated power management unit circuit. The main control unit forms a bidirectional data interaction with an external hardware storage unit circuit, an RJ45 network port isolated communication unit circuit, an RS485 isolated communication unit circuit, an RS232 isolated communication unit circuit, a digital signal isolated output circuit, and a digital signal isolated input circuit.

[0006] The isolated power management unit circuit adopts a three-level redundant architecture of 'input isolation-intermediate step-down-output isolation', including an input DC-DC isolated power supply module and peripheral reverse connection protection, TVS lightning protection circuit, two independent LDO step-down chips and peripheral filtering circuit, and an output DC-DC isolated power supply module and peripheral filtering circuit, to achieve a wide voltage range of DC9~36V power input and electrical isolation between various functional units.

[0007] The external hardware storage unit circuit adopts a dual-redundant storage design of EEPROM and FLASH. EEPROM is used to store configuration parameters and key status data, while FLASH is used to store massive amounts of acquired data. Both communicate with the main control unit through I2C and SPI buses respectively to ensure data storage reliability.

[0008] The RJ45 network port isolation communication unit circuit, RS485 isolation communication unit circuit, RS232 isolation communication unit circuit, digital signal isolation output circuit, and digital signal isolation input circuit all integrate independent digital isolators and TVS lightning protection circuits, forming full signal link isolation protection. It covers a total of 19 isolation interfaces in 5 categories, including RJ45, 2 RS485, 2 RS232, 3 digital signal inputs, and 2 digital signal outputs, and supports Modbus protocol and 7 proprietary communication protocols.

[0009] Preferably, the VCC-5V output from the input DC-DC isolated power supply module URB2405S-6WR3 powers both the two LDO step-down chips SSP7603P33PR and the output DC-DC isolated power supply module B0505S-2WR3. One LDO output W5500-3.3V powers the RJ45 network port isolated communication unit circuit separately, while the other LDO output VCC-3.3V powers the main control unit circuit and the external hardware storage unit circuit. The output DC-DC module outputs A-5V to power the communication interface and the isolated back-end functional circuit, thus achieving independent power supply isolation for each functional unit and avoiding the impact of a single unit failure on the overall circuit.

[0010] Preferably, the RJ45 network port isolation communication unit circuit includes an RJ45 Ethernet isolation connector, an Ethernet controller, and peripheral circuitry. The Ethernet controller is a W5500, and filter capacitors C22-C25 and current-limiting resistors R6-R14 are connected in series between it and the RJ45 isolation connector HR911105A to achieve anti-interference and surge protection for Ethernet signals.

[0011] Preferably, the RS485 isolated communication unit circuit includes two RS485 transceivers MAX485ESA, which support the Modbus protocol and seven proprietary communication protocols respectively. The two circuits are independently configured with digital isolators CA-IS3731HN and TVS diodes SM712. When one RS485 circuit fails, the other can switch over to take over data acquisition, thus achieving communication link redundancy.

[0012] Preferably, the RS232 isolated communication unit circuit includes an RS232 dual transceiver MAX3232ESE, and the two circuits are independently configured with a digital isolator CA-IS3721HS and a bidirectional TVS diode SMBJ15CA. When one RS232 circuit fails, the other can switch over to take over data acquisition, thereby achieving communication link redundancy.

[0013] Preferably, in the digital signal isolation output circuit, the digital isolator CA-IS3730HN is connected to external transistors BG1 and BG2 and pull-down resistors R36 and R46 to form a switch protection circuit. When the output terminal is short-circuited, the pull-down resistor limits the current to ≤50mA to prevent the transistors from burning out.

[0014] Preferably, in the digital signal isolation input circuit, the external diodes D10-D12 of the digital isolator CA-IS3730HN and the filter resistors R19, R27, and R28 form a reverse connection protection and spike protection circuit, which can withstand reverse impacts of input voltage ≤1KV.

[0015] Preferably, the main control unit is a single-chip microcomputer STM32F103VCT6, an external passive low-frequency crystal oscillator XKXGI-SUA-32.768K and an external passive high-frequency crystal oscillator X50328MSB2GI, together with oscillation capacitors C8, C9, C11 and C12, to provide a stable control core for system operation.

[0016] The advantages of this utility model are: It features high temperature resistance and electromagnetic protection performance. The selected components have a minimum operating temperature of over 85℃. At the same time, the circuit adopts a fully isolated design from DC power input, RJ45 Ethernet communication, RS485 communication, RS232 communication to digital signal output and digital signal input, forming a complete signal link isolation protection.

[0017] It has a wide variety and quantity of communication interfaces, including 19 isolated interfaces in 5 categories such as RJ45 Ethernet communication, RS485 communication, RS232 communication, digital signal output, and digital signal input.

[0018] It is compatible with a wide range of communication protocols, supporting Modbus protocol and 7 proprietary communication protocols. It can read and parse data from various devices and upload it to the backend system in a unified communication protocol format. Attached Figure Description

[0019] Figure 1 This utility model has a schematic diagram of its distribution structure.

[0020] Figure 2 This utility model presents a schematic diagram of the isolated power management unit circuit.

[0021] Figure 3 This utility model presents a schematic diagram of the external hardware storage unit circuit.

[0022] Figure 4 This utility model presents a schematic diagram of the RJ45 network port isolation communication unit circuit.

[0023] Figure 5 This utility model presents a schematic diagram of an RS485 isolated communication unit circuit.

[0024] Figure 6 This utility model presents a schematic diagram of an RS232 isolated communication unit circuit.

[0025] Figure 7 This utility model presents a schematic diagram of a digital signal isolation output circuit.

[0026] Figure 8 This utility model presents a schematic diagram of a digital signal isolation input circuit. Detailed Implementation

[0027] The embodiments of this utility model will now be described in detail with reference to the accompanying drawings. Example

[0028] See Figure 1 As shown, this is a schematic diagram of the distributed structure of the present invention. The main control unit is powered by the isolated power management unit circuit, and the main control unit forms a bidirectional data interaction with the external hardware storage unit circuit, the RJ45 network port isolated communication unit circuit, the RS485 isolated communication unit circuit, the RS232 isolated communication unit circuit, the digital signal isolated output circuit, and the digital signal isolated input circuit.

[0029] See Figure 2 The diagram shows the circuit diagram of the isolated power management unit of this utility model. An external DC 9~36V power supply is connected via a screw-type terminal block P1. The negative terminal of the external power supply is connected to pin 1 of the DC-DC isolated power module URB2405S-6WR3, and the positive terminal is connected to pin 2 of URB2405S-6WR3 via a reverse polarity protection diode D3. Simultaneously, a TVS diode D2, capacitors C20 and C21 are connected in parallel to ground at pin 2. Pins 6 and 7 of the DC-DC isolated power module URB2405S-6WR3 output voltage VCC-5V. This voltage VCC-5V is then stepped down by an LDO chip U17, model number [missing information]. The SSP7603P33PR, with an output voltage of W5500-3.3V, is used to power the RJ45 network port isolated communication unit. The voltage VCC-5V is passed through the LDO step-down chip U11, model SSP7603P33PR, with an output voltage of VCC-3.3V, used to power the main control unit circuit and external hardware storage unit circuit. The voltage VCC-5V is passed through the output DC-DC isolated power supply module U5, model B0505S-2WR3, with an output voltage of A-5V, used to power the RS485 isolated output terminal, RS232 isolated output terminal, digital signal isolated output terminal, and digital signal isolated input terminal.

[0030] See Figure 3The diagram shows the external hardware storage unit circuit of this utility model. The external EEPROM memory U3 is model AT24C256CM / TR. Pins 6 and 5 of U3 are connected to pins PB10 and PB11 of the main control unit U1, and external pull-up resistors R3 and R4 are connected to VCC-3.3V. The external FLASH memory U2 is model W25Q64JVSSIQ. Pins 1, 6, 2, and 5 of U2 are connected to pins PA4, PA5, PA6, and PA7 of the main control unit U1, respectively.

[0031] See Figure 4 The diagram shows the circuit diagram of the RJ45 Ethernet isolation communication unit of this utility model. The RJ45 Ethernet isolation connector J2 is model HR911105A; the Ethernet controller U6 is model W5500; pin 6 of J2 connects to pin 5 of U6 via C23 (RX_N); pin 3 of J2 connects to pin 6 of U6 via C24 (RX_P); RX_N and RX_P are connected to pin 5 of J2 via R6 and R7 respectively; pin 5 of J2 is also connected to GND via C22; pin 2 of J2 connects to pin 1 of U6 (TX_N); pin 3 of J2 connects to pin 2 of U6 (TX_P); TX_N and TX_P are externally connected to pull-up resistors R8 and R9 to AVDD-3.3V respectively; pin 4 of J2 is externally connected to pull-up resistor R10 to AVDD. -3.3V and filter capacitor C25 are connected to GND; pin 8 of J2 is connected to GND; pins 9 and 12 of J2 are connected to AVDD-3.3V through resistors R11 and R12 respectively; pin 10 of J2 is LINKLED and connected to pin 25 of U6; pin 11 of J2 is ACTLED and connected to pin 27 of U6; LED1 and LED2 are added to indicate network status. The control terminal SPDLED is connected to pin 24 of U6, and the control terminal DUPLED is connected to pin 26 of U6; pins 30 and 31 of Ethernet controller U6 are connected to an external crystal oscillator XT3; pins 32, 33, 34, 35, 36, and 37 of U6 are connected to PD7, PB3, PB4, PB5, PB6, and PB7 of main control unit U1 respectively.

[0032] See Figure 5The diagram shows a schematic of the RS485 isolated communication unit circuit of this utility model. The first digital isolator U8 is model CA-IS3731HN. Pins 3, 4, and 5 of U8 are connected to PA11, PA9, and PA10 of the main control unit U1, respectively, serving as the signal isolation front end. Pins 12 and 13 of U8 are connected to pins 1 and 4 of the RS485 transceiver U9, model MAX485ESA, respectively. Pin 14 of U8 is connected to pins 2 and 3 of U9. Pin 6 of U9 is pulled up. Resistor R33 and current-limiting resistor R30 form the first RS485 signal A, labeled RS485A1-A. Pin 7 of U9, through pull-down resistor R22 and current-limiting resistor R23, forms the first RS485 signal B, labeled RS485A1-B. A TVS diode D4 (model SM712) is connected in parallel to ground between pins 6 and 7 of U9. The first RS485 signal A and B are connected in parallel to nine screw-type terminals 485A1 to 485A9. The first RS485 signal is mainly connected to Modbu... For industrial equipment connection via the S protocol, the second digital isolator U10 (model CA-IS3731HN) has pins 3, 4, and 5 connected to PD10, PD8, and PD9 of the main control unit U1, respectively, serving as the signal isolation front end. Pins 12 and 13 of U10 are connected to pins 1 and 4 of the RS485 transceiver U16 (model MAX485ESA), respectively, and pin 14 of U10 is connected to pins 2 and 3 of U16. Pin 6 of U16 is connected via pull-up resistor R44 and current-limiting resistor. R41 is the A of the second RS485 signal, labeled RS485B1-A. Pin 7 of U16, through pull-down resistor R35 and current-limiting resistor R37, is the B of the second RS485 signal, labeled RS485B1-B. Pins 6 and 7 of U16 are connected in parallel to ground with TVS diode D5, model SM712. The A and B of the second RS485 signal are connected in parallel to two screw terminals 485B1 to 485B2. The second RS485 signal is mainly connected to industrial equipment with proprietary communication protocols.

[0033] See Figure 6The diagram shows a schematic of the RS232 isolated communication unit circuit of this utility model. The first digital isolator U15 is model CA-IS3721HS. Pins 2 and 3 of U15 are connected to pins PA2 and PA3 of the main control unit U1, respectively, serving as the signal isolation front end. Pins 7 and 6 of U15 are connected to pins 11 and 12 of the RS232 transceiver U14, model MAX3232ESE, respectively. Pin 13 of U14 is the RX of the first RS232 signal, labeled RS232A-RX, and pin 14 of U14 is the TX of the first RS232 signal, labeled RS232A-TX. TVS diodes D7 and D6, both model SMBJ15CA, are connected in parallel to ground for both RS232A-RX and RS232A-TX. The final pins of the first RS232 signal RS232A-RX and RS232A-TX are... The signal is connected to the screw-type terminal block 232A; the second digital isolator U13, model CA-IS3721HS, has pins 2 and 3 connected to pins PC10 and PC11 of the main control unit U1, respectively, serving as the signal isolation front end; pins 7 and 6 of U13 are connected to pins 10 and 9 of the RS232 transceiver U14, model MAX3232ESE, respectively; pin 8 of U14 is the RX of the second RS232 signal, labeled RS232B-RX, and pin 7 of U14 is the TX of the second RS232 signal, labeled RS232B-TX. RS232B-RX and RS232B-TX are connected in parallel to ground with TVS diodes D9 and D8, both model SMBJ15CA. The RS232B-RX and RS232B-TX of the second RS232 signal are finally led to the screw-type terminal block 232B.

[0034] See Figure 7 The diagram shows a schematic of the digital signal isolation output circuit of this utility model. The digital isolator U12 is model CA-IS3730HN. Pins 3 and 4 of U12 are connected to pins PE1 and PE0 of the main control unit U1, respectively, serving as the signal isolation front end. The first digital signal isolation output is controlled by transistor BG1 via resistor R39 through pin 14 of U12. Transistor BG1 and pull-down resistor R36 are connected to screw terminal OUT1. The second digital signal isolation output is controlled by transistor BG2 via resistor R40 through pin 13 of U12. Transistor BG2 and pull-down resistor R46 are connected to screw terminal OUT2.

[0035] See Figure 8The diagram shows a schematic of the digital signal isolation input circuit of this utility model. The digital isolator U7 is model CA-IS3730HN. Pins 12, 13, and 14 of U7 are connected to pins PE4, PE3, and PE2 of the main control unit U1, respectively, serving as the signal isolation front end. The first digital signal isolation input is connected to the screw terminal INT1 via pin 5 of U7 through a filter resistor R27, a pull-up resistor R21, and a diode D10. The second digital signal isolation input is connected to the screw terminal INT2 via pin 4 of U7 through a filter resistor R28, a pull-up resistor R25, and a diode D11. The third digital signal isolation input is connected to the screw terminal INT3 via pin 3 of U7 through a filter resistor R19, a pull-up resistor R34, and a diode D12.

[0036] In addition to the embodiments described above, this utility model may have other implementations. All technical solutions employing equivalent substitutions or transformations fall within the protection scope claimed by this utility model.

Claims

1. A redundancy circuit for an industrial harvesting gateway comprising a master unit, characterized in that, The main control unit is powered by the isolated power management unit circuit, and the main control unit forms a two-way data interaction with the external hardware storage unit circuit, the RJ45 network port isolated communication unit circuit, the RS485 isolated communication unit circuit, the RS232 isolated communication unit circuit, the digital signal isolated output circuit, and the digital signal isolated input circuit. The isolated power management unit circuit adopts a three-level redundant architecture of 'input isolation-intermediate step-down-output isolation', including an input DC-DC isolated power module and peripheral reverse connection protection, TVS lightning protection circuit, two independent LDO step-down chips and peripheral filter circuit, and an output DC-DC isolated power module and peripheral filter circuit, to achieve DC9~36V wide voltage range power input and electrical isolation between each functional unit; The external hardware storage unit circuit adopts a dual storage redundancy design of EEPROM and FLASH. EEPROM is used to store configuration parameters and key status data, and FLASH is used to store massive amounts of acquired data. Both interact with the main control unit through I2C and SPI buses respectively to ensure data storage reliability. The RJ45 network port isolation communication unit circuit, RS485 isolation communication unit circuit, RS232 isolation communication unit circuit, digital signal isolation output circuit, and digital signal isolation input circuit all integrate independent digital isolators and TVS lightning protection circuits, forming full signal link isolation protection. It covers a total of 19 isolation interfaces in 5 categories, including RJ45, 2 RS485, 2 RS232, 3 digital signal inputs, and 2 digital signal outputs, and supports Modbus protocol and 7 proprietary communication protocols.

2. The redundancy circuit for an industrial harvesting gateway of claim 1, wherein, The input DC-DC isolated power supply module URB2405S-6WR3 outputs VCC-5V to power two LDO step-down chips SSP7603P33PR and the output DC-DC isolated power supply module B0505S-2WR3. One LDO outputs W5500-3.3V to power the RJ45 network port isolated communication unit circuit, while the other LDO outputs VCC-3.3V to power the main control unit circuit and the external hardware storage unit circuit. The output DC-DC module outputs A-5V to power the communication interface and the isolated back-end functional circuit, realizing independent power supply isolation for each functional unit and avoiding the impact of a single unit failure on the overall circuit.

3. The redundancy circuit for an industrial harvesting gateway of claim 1, wherein, The RJ45 network port isolation communication unit circuit includes an RJ45 Ethernet isolation connector, an Ethernet controller, and peripheral circuits. The Ethernet controller is a W5500, and filter capacitors C22-C25 and current-limiting resistors R6-R14 are connected in series between it and the RJ45 isolation connector HR911105A to achieve anti-interference and surge protection for Ethernet signals.

4. The redundancy circuit for an industrial harvesting gateway of claim 1, wherein, The RS485 isolated communication unit circuit includes two RS485 transceivers MAX485ESA, which support the Modbus protocol and seven proprietary communication protocols respectively. The two circuits are independently configured with digital isolators CA-IS3731HN and TVS diodes SM712. When one RS485 circuit fails, the other can switch over to take over data acquisition, thus achieving communication link redundancy.

5. The redundancy circuit for an industrial harvesting gateway of claim 1, wherein, The RS232 isolated communication unit circuit includes an RS232 dual transceiver MAX3232ESE. The two circuits are independently configured with a digital isolator CA-IS3721HS and a bidirectional TVS diode SMBJ15CA. When one RS232 circuit fails, the other can be switched to take over data acquisition, thus achieving communication link redundancy.

6. The redundancy circuit for an industrial harvesting gateway of claim 1, wherein, In the digital signal isolation output circuit, the digital isolator CA-IS3730HN is connected to external transistors BG1 and BG2 and pull-down resistors R36 and R46 to form a switch protection circuit. When the output terminal is short-circuited, the pull-down resistor limits the current to ≤50mA to prevent the transistors from burning out.

7. The redundancy circuit for an industrial harvesting gateway of claim 1, wherein, In the digital signal isolation input circuit, the external diodes D10-D12 of the digital isolator CA-IS3730HN, together with the filter resistors R19, R27, and R28, form a reverse connection protection and spike protection circuit, which can withstand reverse impacts of input voltage ≤1KV.

8. The redundancy circuit for an industrial harvesting gateway of claim 1, wherein, The main control unit consists of a single-chip microcomputer STM32F103VCT6, an external passive low-frequency crystal oscillator XKXGI-SUA-32.768K, and an external passive high-frequency crystal oscillator X50328MSB2GI, along with oscillation capacitors C8, C9, C11, and C12, providing a stable control core for system operation.

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