Electric explosion-proof mine car whole vehicle controller
The electric explosion-proof mining truck controller, which integrates signal input, output, communication, power supply and grounding units, solves the problems of scattered functions and poor adaptability in the existing technology. It achieves multi-signal compatibility and stable power supply, improves the accuracy of data acquisition and the reliability of power supply, and meets the requirements for safe and efficient operation of underground electric explosion-proof mining trucks.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ORDOS NEW ENERGY RESEARCH & APPLICATION CO LTD
- Filing Date
- 2025-11-03
- Publication Date
- 2026-08-04
AI Technical Summary
Existing electric explosion-proof mining truck controllers suffer from low functional integration, poor adaptability, and insufficient explosion-proof performance and power supply stability. They cannot simultaneously accommodate multiple signal types and power supply requirements, resulting in inaccurate data acquisition, frequent power supply failures, and an inability to meet the safe and efficient operation requirements of complex underground environments.
An electric explosion-proof mining truck controller was designed, integrating a signal input unit, a signal output unit, a communication unit, a power supply unit, and a grounding unit. It includes analog quantity, switch quantity, hard-wired wake-up, and frequency quantity input modules, and has OC output and external low-voltage power supply functions. It achieves compatibility with multiple signals and stable power supply, and adopts an independent communication protocol and isolated ground design to enhance communication compatibility.
It achieves simultaneous compatible acquisition and output of multiple signals, reduces signal transmission interference, improves data acquisition accuracy and power supply stability, reduces failure rate, and meets the intelligent monitoring and collaborative control requirements of underground electric explosion-proof mining trucks.
Smart Images
Figure CN224595023U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of controller technology, specifically to a whole vehicle controller for an electric explosion-proof mining truck. Background Technology
[0002] The overall control logic of electric explosion-proof mining trucks is far more complex than that of traditional mining trucks. It is necessary to achieve coordinated control of multiple modules such as drive system, braking system, steering system, and safety monitoring system, which puts forward higher technical requirements for the core control component - the vehicle controller.
[0003] Currently, many existing mining vehicle controllers on the market suffer from low functional integration, poor adaptability, and insufficient explosion-proof performance and power supply stability. On the one hand, the signal acquisition modules of traditional controllers often only support a single type of signal input, such as only processing analog or switch signals. They cannot simultaneously handle analog signals from external sensors (such as speed sensors and pressure sensors), switch signals from equipment status switches, frequency signals of motor speed, and hard-wired signals of vehicle wake-up commands. This necessitates the additional configuration of multiple independent acquisition devices, which not only increases the size and installation complexity of the controller but also makes it prone to interference due to excessively long signal transmission links, affecting the accuracy of data acquisition. On the other hand, in the signal output stage, the output functions of existing controllers are relatively simple. Most can only output control signals and cannot simultaneously provide stable power to external low-power devices (such as small sensors and indicator lights). This requires an additional independent power supply module, which not only increases the wiring difficulty and cost of the entire vehicle but may also cause power supply failures due to compatibility issues between the power supply module and the controller. Furthermore, some controllers use a single communication protocol, making it difficult to adapt to the communication needs of different on-board electronic devices (such as battery management systems, motor controllers, and on-board terminals) in electric explosion-proof mining trucks. This results in the risk of data interaction delays or interruptions, failing to meet the requirements for intelligent monitoring and collaborative control of the entire vehicle. In summary, the current field of electric explosion-proof mining vehicles urgently needs a vehicle controller with high integration, comprehensive signal processing capabilities, stable and reliable power supply, strong communication compatibility, and good explosion-proof grounding performance. This controller would solve the problems of functional dispersion, low reliability, and poor adaptability in existing technologies, and meet the safe and efficient operation requirements of electric explosion-proof mining vehicles in complex underground environments. Utility Model Content
[0004] To address the aforementioned technical problems, this application provides a whole-vehicle controller for an electric explosion-proof mining truck.
[0005] The technical solution adopted by this utility model to solve its technical problem is: an electric explosion-proof mining car whole vehicle controller, including a main control unit, a signal input unit, a signal output unit, a communication unit, a power supply unit and a grounding unit; The signal input unit is used to acquire signals from external sensors and switching devices, including an analog input module, a digital input module, a hard-wired wake-up module, and a frequency input module; The signal output unit is used to output control signals and provide external power, including an OC output module and an external low-voltage power supply module; The communication unit is used to interact with other on-board electronic devices of the electric explosion-proof mining truck. The power supply unit is used to provide 12V power to the controller and external associated devices, and includes at least two independent power supply channels.
[0006] The analog input module includes at least 12 acquisition channels, of which at least 8 are voltage acquisition channels and at least 4 are current acquisition channels; The voltage-type acquisition channel is equipped with a pull-up resistor to receive a 5V voltage signal, and the output voltage is 4.95V when the signal is floating. The current-type acquisition channel is equipped with pull-down resistors with an accuracy of not less than 1% to receive 4-20mA current signals, and the output voltage is less than 0.3V when the signal is floating.
[0007] The digital input module includes at least 24 ordinary digital input channels and at least 1 special digital input channel; The ordinary switch quantity acquisition channel is equipped with a pull-up resistor and adopts a low-active-trigger mode. The high-level trigger threshold is greater than 3V and the low-level trigger threshold is less than 1V. The special switch quantity acquisition channel is connected to the AD acquisition interface of the main control unit through a resistor voltage divider circuit to realize signal acquisition.
[0008] The hardwired wake-up module adopts a high-effectiveness triggering method, with an input voltage range of 0-12V, a high-level trigger threshold greater than 6V, and a low-level trigger threshold less than 1V. The output terminal of the hardwired wake-up module is electrically connected to the wake-up control pin of the main control unit to trigger the controller's power-on logic.
[0009] The frequency input module includes at least 6 frequency signal acquisition channels. The frequency receiving range of all channels is 200Hz-1000Hz, the high-level trigger threshold is greater than 3V, and the low-level trigger threshold is less than 1V. At least four of the frequency signal acquisition channels are equipped with pull-up resistors, and at least two of the channels equipped with pull-up resistors have phase relationship detection function; At least two of the remaining frequency signal acquisition channels are not equipped with pull-up resistors.
[0010] The OC output module includes at least 6 OC output channels, each of which is equipped with a current-limiting resistor and has short-circuit protection function; The input terminal of the OC output module is electrically connected to the GPIO pin of the main control unit, and the output terminal is used to connect to an external actuator.
[0011] The external low-voltage power supply module is a low-dropout voltage regulator; The control terminal of the external low-voltage power supply module is electrically connected to the power management pin of the main control unit, and the output terminal supplies power to external sensors through at least 11 power supply interfaces.
[0012] The first 12V power supply channel of the power supply unit is used to power the main control unit and the 12V external sensor, and this power supply channel has at least two optional solder joints for adapting to 5V external sensors. The second 12V power supply channel of the power supply unit is independently used to power the vehicle instrument and is not electrically connected to the main control unit.
[0013] The grounding network of the grounding unit includes sensor ground, power ground and CAN isolation ground; The sensor ground is used to connect the signal input unit and the load ground of the external low-voltage power supply module; The power ground is used to connect the logic ground of the power supply unit and the main control unit; The CAN isolation ground is physically isolated from the sensor ground and power ground, and each CAN communication channel corresponds to an independent CAN isolation ground.
[0014] The beneficial effects of this utility model are as follows: 1. The signal input unit includes an analog input module, a digital input module, a hard-wired wake-up module, and a frequency input module. It is simultaneously compatible with analog signals from external sensors (such as speed sensors and pressure sensors), digital signals from equipment status switches, frequency signals from motor speed, and hard-wired signals from vehicle wake-up commands, eliminating the need for multiple independent acquisition devices. This not only shortens the signal transmission path and reduces the impact of external interference on the signal, but also improves the accuracy and real-time performance of data acquisition.
[0015] 2. The signal output unit has dual functions: "outputting control signals" and "providing external power." The OC output module can stably output control signals to meet the control requirements of the drive, braking, and steering actuators of the electric explosion-proof mining truck. The external low-voltage power supply module can directly provide power to external low-power devices (such as small monitoring sensors and status indicator lights) without the need for an additional independent power supply module. This not only avoids power supply failures caused by poor compatibility between the external power supply module and the controller, but also reduces the number of power-related components in the entire vehicle, lowering the potential points of failure. Attached Figure Description
[0016] Figure 1 This is a schematic diagram of the structure of the electric explosion-proof mining truck controller in the embodiments of this application; Figure 2 This is a schematic diagram of the analog pull-up resistor configuration circuit in the embodiments of this application; Figure 3 This is a schematic diagram of the current-type signal acquisition circuit in an embodiment of this application; Figure 4 This is a schematic diagram of the low active switching quantity interface circuit in the embodiments of this application; Figure 5 This is a schematic diagram of the frequency input circuit (with pull-up configuration) in an embodiment of this application; Figure 6 This is a schematic diagram of the frequency input circuit (without pull-up configuration) in an embodiment of this application; Figure 7 This is a schematic diagram of the isolated CAN communication interface circuit in an embodiment of this application; Figure 8 This is a schematic diagram of the 5V power output interface circuit in an embodiment of this application. Detailed Implementation
[0017] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.
[0018] Example: An electric explosion-proof mining truck controller includes a main control unit, a signal input unit, a signal output unit, a communication unit, a power supply unit, and a grounding unit. In a specific implementation, the main control unit uses a 32-bit microcontroller, AURIX TC234LP, as the core computing and control unit of the controller. It integrates a 200MHz main frequency / bus frequency, 2MB Flash, 192KB RAM, and has resources such as 24-channel 12-bit AD acquisition, 6-channel CAN interface supporting CANFD, 4-channel SPI, and 2 STMx1 timers. It also features DMA, GTM, and Lockstep protection cores and is the core of all signal processing, logic control, and communication interaction.
[0019] The signal input unit includes: Analog input interface module: contains 12 acquisition channels, divided into 8 voltage type (pull-up 100K resistor) and 4 current type (pull-down 220R / 1% resistor), corresponding to pins such as J1001-2 (I_A_V_1), J1003-2 (I_A_mA_1), etc., used to receive 0.5V voltage signals or 420mA current signals from external sensors (such as pressure and position sensors).
[0020] Digital input interface module: includes 24 channels of general digital input (pull-up 10K resistor, active low) and 1 channel of T50 signal (resistor voltage divider + AD acquisition), corresponding to pins such as J1008-5 (I_S_1), J1010-6 (I_S_T50), etc., used to receive on / off signals from switching devices (such as light switches, brake switches).
[0021] Hard-wire wake-up signal interface: 1 active wake-up channel, corresponding to pin J1010-5 (I_KEY_IN), receives 0-12V wake-up signal (high level > 6V trigger) to control VCU power-on.
[0022] Frequency input interface module: 6 acquisition channels, 4 pull-up 2.2K resistors (including 2 channels with phase relationship for angle measurement), 2 non-pull-up resistors (dedicated to CO / CH4 sensor), corresponding pins such as J1007-8 (I_F_1), J1003-8 (I_F_3), etc., receiving frequency signals from 200Hz to 1000Hz.
[0023] The signal output unit includes: OC output interface module: 6 OC output channels with short-circuit protection, with a 1K current-limiting resistor in series at the output end, corresponding to pins such as J1010-8 (O_OCTR1), J1004-1 (O_OCTR4), etc., used to drive external actuators (such as relays).
[0024] External 5V power supply module: 1 independent 5V output (maximum total current 150mA, with short circuit protection), with 11 pins for output, corresponding to pins such as J1001-1 (V_A5V1), J1001-4, etc., to power external 5V sensors.
[0025] The communication unit includes: CAN communication interface module: 6 isolated CAN channels, each containing CANL, CANH and isolation ground, with corresponding pins such as J1011-1 / 2 / 3 (CAN1), J1005-7 / 8 / 9 (CAN2), etc., baud rate 250kbps, hardware unsoldered terminating resistors, used for data interaction with other controllers of the mining truck (such as motor controllers and instruments).
[0026] Power supply and grounding unit Power input interface: 2 12V power supply channels. The first channel (V_A12V_1IN) corresponds to pins J1003-1 / 4 / 7, etc., which power the VCU and 12V sensor (some pins are reserved for optional soldering to adapt to 5V sensors); the second channel (V_A12V_2) corresponds to pins J1012-7 / 9, which only power the instrument and is not connected to the VCU.
[0027] Grounding network: includes sensor ground (corresponding pin such as J1001-3), power ground (corresponding pin such as J1012-6), and CAN isolation ground (each CAN channel is independent, corresponding pin such as J1011-3). The three types of grounding are physically isolated to avoid interference.
[0028] When the above units are connected, they are centered around the main control microcontroller, and input / output / communication / power supply all interact around it. Analog input module: 12 analog signals (voltage / current type) are connected to the microcontroller's 24 AD acquisition pins after passing through the interface circuit (pull-up / pull-down resistors, filtering) to realize the digitization of sensor signals.
[0029] Digital input module: 24 ordinary switch signals are connected to the GPIO pin of the microcontroller after passing through pull-up resistor circuits and 1 T50 signal is connected to the voltage divider circuit to trigger level detection; the hard-wired wake-up signal (I_KEY_IN) is directly connected to the wake-up pin of the microcontroller to trigger the power-on logic.
[0030] Frequency input module: After passing through the current limiting and filtering circuit, the 6-channel frequency signals are connected to the timer capture pin of the microcontroller to realize frequency and phase (angle measurement channel) detection.
[0031] OC output module: The microcontroller outputs control signals through its GPIO pins. After passing through the OC driver circuit (with short-circuit protection and 1K current limiting), the signals are connected to an external actuator via 6 OC output pins to execute control commands.
[0032] External 5V power supply module: The microcontroller controls the LDO (low dropout regulator) through the power management pin to output a 5V voltage, which powers the external 5V sensor through 11 power supply pins. At the same time, the LDO has a short circuit protection feedback function to notify the microcontroller in case of abnormality.
[0033] CAN communication module: The 6 CAN controller pins of the microcontroller are connected to the CANL / CANH pins of the 6 CAN channels after isolation circuit (common mode inductor, isolation chip). Each CAN channel is equipped with an independent isolation ground, which is isolated from other ground lines to ensure communication anti-interference. The microcontroller realizes data transmission and reception with external devices through the CAN protocol stack.
[0034] The first 12V power supply (V_A12V_1IN): After power filtering and voltage regulation circuit, it is divided into two paths. One path powers the microcontroller (provides the core operating voltage), and the other path directly powers the 12V sensor (through the corresponding pins). The reserved optional pins are connected to the 5V sensor through voltage divider / regulator and then powered.
[0035] The second 12V power supply (V_A12V_2): It connects directly to the instrument through a dedicated pin, without going through the internal circuit of the VCU, and independently powers the instrument.
[0036] Sensor ground: The signal ground of the analog / digital / frequency input modules and the load ground of the external 5V power supply modules are all connected to the sensor ground network. They are kept independent before being finally connected to the power ground to avoid signal interference.
[0037] Power ground: The power supply ground of the power input module, the ground of the microcontroller and internal logic circuits are all connected to the power ground network to provide a reference ground for the entire controller.
[0038] CAN isolation ground: The isolation chip ground of each CAN communication module is independently connected to the corresponding CAN isolation ground pin, which is physically disconnected from the sensor ground and power ground. It is only grounded externally through the mine car grounding system to prevent communication interference.
[0039] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.
Claims
1. A whole-vehicle controller for an electric explosion-proof mining car, characterized in that, It includes a main control unit, a signal input unit, a signal output unit, a communication unit, a power supply unit, and a grounding unit; The signal input unit is used to acquire signals from external sensors and switching devices, including an analog input module, a digital input module, a hard-wired wake-up module, and a frequency input module; The signal output unit is used to output control signals and provide external power, including an OC output module and an external low-voltage power supply module; The communication unit is used to interact with other on-board electronic devices of the electric explosion-proof mining truck. The power supply unit is used to provide 12V power to the controller and external associated devices, and includes at least two independent power supply channels.
2. The electric explosion-proof mining car controller according to claim 1, characterized in that, The analog input module includes at least 12 acquisition channels, of which at least 8 are voltage acquisition channels and at least 4 are current acquisition channels; The voltage-type acquisition channel is equipped with a pull-up resistor to receive a 0.5V voltage signal, and the output voltage is 4.95V when the signal is floating. The current-type acquisition channel is equipped with pull-down resistors with an accuracy of not less than 1% to receive 4-20mA current signals, and the output voltage is less than 0.3V when the signal is floating.
3. The electric explosion-proof mining car controller according to claim 1, characterized in that, The digital input module includes at least 24 ordinary digital input channels and at least 1 special digital input channel; The ordinary switch quantity acquisition channel is equipped with a pull-up resistor and adopts a low-active-trigger mode. The high-level trigger threshold is greater than 3V and the low-level trigger threshold is less than 1V. The special switch quantity acquisition channel is connected to the AD acquisition interface of the main control unit through a resistor voltage divider circuit to realize signal acquisition.
4. The electric explosion-proof mining car controller according to claim 1, characterized in that, The hardwired wake-up module adopts a high-effectiveness triggering method, with an input voltage range of 0-12V, a high-level trigger threshold greater than 6V, and a low-level trigger threshold less than 1V. The output terminal of the hardwired wake-up module is electrically connected to the wake-up control pin of the main control unit to trigger the controller's power-on logic.
5. The electric explosion-proof mining car controller according to claim 1, characterized in that, The frequency input module includes at least 6 frequency signal acquisition channels. The frequency receiving range of all channels is 200Hz to 1000Hz. The high-level trigger threshold is greater than 3V and the low-level trigger threshold is less than 1V. At least four of the frequency signal acquisition channels are equipped with pull-up resistors, and at least two of the channels equipped with pull-up resistors have phase relationship detection function; At least two of the remaining frequency signal acquisition channels are not equipped with pull-up resistors.
6. The electric explosion-proof mining car controller according to claim 1, characterized in that, The OC output module includes at least 6 OC output channels, each of which is equipped with a current-limiting resistor and has short-circuit protection function; The input terminal of the OC output module is electrically connected to the GPIO pin of the main control unit, and the output terminal is used to connect to an external actuator.
7. The electric explosion-proof mining car controller according to claim 1, characterized in that, The external low-voltage power supply module is a low-dropout voltage regulator; The control terminal of the external low-voltage power supply module is electrically connected to the power management pin of the main control unit, and the output terminal supplies power to external sensors through at least 11 power supply interfaces.
8. The electric explosion-proof mining car controller according to claim 1, characterized in that, The first 12V power supply channel of the power supply unit is used to power the main control unit and the 12V external sensor, and this power supply channel has at least two optional solder joints for adapting to 5V external sensors. The second 12V power supply channel of the power supply unit is independently used to power the vehicle instrument and is not electrically connected to the main control unit.
9. The electric explosion-proof mining car controller according to claim 1, characterized in that, The grounding network of the grounding unit includes sensor ground, power ground and CAN isolation ground; The sensor ground is used to connect the signal input unit and the load ground of the external low-voltage power supply module; The power ground is used to connect the logic ground of the power supply unit and the main control unit; The CAN isolation ground is physically isolated from the sensor ground and power ground, and each CAN communication channel corresponds to an independent CAN isolation ground.