Remote IO system with internet of things function

Abstract

The utility model discloses a kind of remote IO systems with internet of things function, it is related to internet of things technical field, including structure shell, main control circuit board and mobile terminal.Circuit board is integrated with micro control unit, internet of things communication module, data storage module, power management module, digital / analog input / output module.Micro control unit is connected each module by bus, built-in edge computing module, for IO data filtering, PT range conversion and threshold value determination and so on pretreatment.Internet of things communication module supports Bluetooth, WiFi and 4G multimode communication, realize with cloud platform or local gateway two-way transmission.Data storage module supports temporary storage data when off-line, automatically supplement after recovery.Mobile terminal wireless connection communication module, for network, monitoring and control.The utility model local processing signal accelerates response, off-line temporary storage recovery supplement, support long-distance transmission and mobile phone network, provide convenient and reliable remote IO solution for industrial field.

Description

Technical Field

[0001] This utility model relates to the fields of industrial automation and Internet of Things (IoT) technology, specifically to a remote I / O system with IoT functionality for industrial field data acquisition and equipment control. Background Technology

[0002] Remote I / O (input / output) systems are an indispensable part of industrial automation control systems. They collect signals from various sensors, switches and other devices distributed in the field and transmit them to the main controller (such as a PLC), or receive instructions from the main controller to control field actuators (such as relays and valves).

[0003] Traditional remote I / O systems mostly rely on wired communication methods (such as RS-485, PROFIBUS, etc.) to connect to the host computer, which has drawbacks such as complex wiring, poor scalability, and difficulty in achieving remote monitoring. Furthermore, in remote or dispersed application scenarios such as oil and gas extraction, smart agriculture, and environmental monitoring, wired communication is costly to deploy and difficult to maintain. Although some existing technologies have begun to incorporate wireless communication, their capabilities in areas such as local data preprocessing, multi-network integration, and data transmission resumption after network outages remain insufficient, failing to meet the growing intelligent demands of the Industrial Internet of Things (IIoT). Utility Model Content

[0004] The purpose of this invention is to provide a remote I / O system with Internet of Things (IoT) functionality to solve the problems mentioned in the background section and achieve efficient data acquisition, wireless transmission, and remote control of industrial field data.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A remote I / O system with IoT functionality includes a structural housing, a main control circuit board housed within the housing, and a mobile terminal. The main control circuit board integrates an IoT communication module, a data storage module, a microcontroller unit, a power management module, a digital input / output (DIO) module, and an analog input / output (AIO) module. The microcontroller unit, as the core control unit, connects to each functional module via three independent buses: an SPI bus to the IoT communication module, a QSPI bus to the data storage module, and an RS485 bus to the DIO and analog input / output modules; it is also electrically connected to the power management module via a power bus, enabling unified scheduling and data interaction among the modules. Simultaneously, the microcontroller unit incorporates an edge computing module, which connects to the DIO, analog input / output, data storage, and IoT communication modules, forming a data transmission link for I / O signal acquisition, local preprocessing, data storage, and wireless remote transmission.

[0007] Furthermore, the mobile terminal connects to the IoT communication module via a wireless network. The IoT communication module is a multi-mode converged communication module integrating Bluetooth, WiFi, and 4G, supporting Bluetooth, WiFi, and 4G wireless communication protocols. It supports dual-mode interaction of local direct connection and remote network connection, and can connect to the cloud platform and local gateway for data interaction, realizing bidirectional data transmission and adapting to cross-regional and high-volume data transmission needs.

[0008] Furthermore, the data storage module uses the AT25SF128A-SHB-T for parameter and location data storage, and has Flash storage management function. When the network is disconnected, the Flash temporarily stores the collected IO data, and after the network is restored, the Flash temporarily stored data is retransmitted to the cloud platform and then transmitted to the mobile terminal for display, ensuring the integrity of the data.

[0009] Furthermore, the edge computing module built into the microcontroller unit performs local preprocessing on the acquired IO data. This local preprocessing includes time filtering, PT range conversion, and threshold judgment. Time filtering employs a delay-based debouncing method to eliminate instantaneous interference in the acquired signal, improving the stability of the raw IO data and obtaining stable and reliable raw acquired data. PT range conversion converts the sensor's raw electrical signal into a standard PT physical quantity. Threshold judgment simultaneously performs data overflow and underflow detection. When the acquired value exceeds preset upper and lower thresholds, an abnormal alarm signal is generated. Simultaneously, the data change amplitude of previous and subsequent periods is compared in real time, and the corresponding data is distributed and transmitted to the IoT communication module based on different input / output types (digital and analog). By performing data preprocessing locally, the edge computing module effectively reduces cloud computing pressure and data transmission bandwidth usage, improves the system's real-time response speed, and adapts to the low-latency operation requirements of IoT scenarios.

[0010] Furthermore, the power management module includes three switching power supplies. These power supplies achieve DC isolation through a power conversion chip, providing 15V, 5V, 3.3V, and 1.8V DC power to each module. The 15V voltage is input to the MP2457GJ-Z DC-DC buck module to generate 5V. The 5V voltage is then connected to the DA9080-61FCB2 voltage regulator chip, which regulates and outputs 3.3V and 1.8V respectively. The 3.3V voltage supplies power to the microcontroller unit, data storage unit, and other functional modules, while the 1.8V voltage provides a reference voltage for the microcontroller unit. This hierarchical isolation power supply architecture avoids power crosstalk between modules, ensuring stable system operation.

[0011] Furthermore, the digital input / output module includes digital input ports and digital output ports. The digital input ports are connected to field switch signal devices, and the digital output ports are connected to field actuator devices.

[0012] Furthermore, the analog input / output module supports the input and output of ±20mA current signals and ±10V voltage signals, connecting to analog sensors and actuators in the industrial field.

[0013] Furthermore, the mobile terminal is used to configure the network connection parameters of the IoT communication module and establish data interaction with the cloud platform. The mobile terminal includes a device configuration module, a data monitoring module, and a remote control module. The device configuration module configures the network access of the IoT communication module, supporting two configuration modes. The first is a wireless LAN configuration mode, in which the mobile terminal sends the scanned WiFi names and entered WiFi passwords to the IoT communication module on the main control circuit board via Bluetooth or WiFi AP hotspot mode. After receiving these parameters, the IoT communication module switches to WiFi STA mode to access the wireless network. The second is a cellular network configuration mode, in which the mobile terminal directly configures the 4G APN parameters to the IoT communication module, enabling the device to connect to the network via the 4G public network. The data monitoring module displays the status information and real-time data of the IO channel, and the remote control module issues operation commands to the remote IO system.

[0014] Furthermore, the structural housing is also equipped with a status indicator array, which includes power indicator lights and IO channel status indicator lights, used to display the working status of the remote IO system, facilitating on-site debugging and troubleshooting.

[0015] Furthermore, the structural housing is equipped with guide rail clips, which are standard DIN guide rail clips, used to detachably install the remote I / O system onto the standard guide rails inside the control cabinet, enabling quick installation and convenient maintenance.

[0016] Compared with the prior art, the beneficial effects of this utility model are:

[0017] Integrating a microcontroller unit, IoT communication module, and I / O interface into one unit, this system not only enables transparent data transmission but also allows for edge computing and protocol conversion via the built-in microcontroller unit. It supports wireless communication, enabling network configuration, data monitoring, and remote control via mobile terminals, enhancing the user experience. Combined with the data storage module's offline resume function, it significantly improves the reliability of data acquisition. The standard DIN rail mounting design simplifies on-site deployment, facilitates rapid installation, and promotes convenient maintenance. Attached Figure Description

[0018] Figure 1 A system structure block diagram of a remote I / O system with Internet of Things (IoT) functionality provided by this utility model;

[0019] Figure 2A schematic diagram of the status indicator array structure of the remote I / O system with Internet of Things (IoT) function provided by this utility model;

[0020] Figure 3 A schematic diagram of the guide rail buckle structure of the remote IO system with Internet of Things (IoT) function provided by this utility model.

[0021] Reference numerals: 1: Status indicator array; 2: Guide rail clip. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are merely embodiments of the present utility model, and all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present utility model.

[0023] like Figure 1 As shown, this embodiment provides a remote I / O system with Internet of Things (IoT) functionality, including a structural housing, a main control circuit board disposed within the structural housing, and a mobile terminal. The main control circuit board integrates an IoT communication module, a data storage module, a microcontroller unit, a power management module, a digital input / output module, and an analog input / output module.

[0024] like Figure 1 As shown, the microcontroller unit (MCU), as the core control unit, connects to various functional modules via three independent buses: the IoT communication module via SPI bus, the data storage module via QSPI bus, the digital input / output module and analog input / output module via RS485 bus, and the power management module via a power bus. The MCU is responsible for acquiring digital and analog signals, performing logic operations, protocol conversion, and issuing commands. The power management module's input is connected to an external power supply, and its output is connected to the MCU, the IoT communication module, and various interface circuits.

[0025] like Figure 1 As shown, in a preferred embodiment, the IoT communication module is a multi-mode converged communication module integrating Bluetooth, WiFi, and 4G, supporting Bluetooth, WiFi, and 4G wireless communication protocols, and supporting dual-mode interaction of local direct connection and remote network connection. This module transmits the IO data processed by the microcontroller unit to the cloud platform or local gateway via a wireless network, while simultaneously receiving control commands from the cloud or gateway.

[0026] like Figure 1As shown, to improve data transmission reliability, especially in industrial environments with unstable networks, a data storage module connected to the microcontroller unit is installed on the main control circuit board. The data storage module uses an AT25SF128A-SHB-T for parameter and location data storage and has Flash storage management capabilities. When the IoT communication module detects a network interruption or cloud server connection failure, the microcontroller unit automatically stores the collected IO data in this data storage module. Once network communication is restored, the microcontroller unit reads the stored data and retransmits it, thus ensuring the integrity and continuity of field data and avoiding data loss due to network fluctuations.

[0027] like Figure 1 As shown, the microcontroller unit incorporates an edge computing module, which connects to the digital input / output module, analog input / output module, data storage module, and IoT communication module, forming a data transmission link for IO signal acquisition, local preprocessing, data storage, and wireless transmission. This edge computing module performs local preprocessing on the acquired IO data, including time filtering, PT range conversion, and threshold judgment. Time filtering uses a delay-based debouncing method to eliminate instantaneous interference in the acquired signal, resulting in stable and reliable raw data. PT range conversion converts the sensor's raw electrical signal into a standard PT physical quantity. Threshold judgment simultaneously performs data overflow and underflow detection. When the acquired value exceeds preset upper and lower thresholds, an abnormal alarm signal is generated. Simultaneously, the data change amplitude of previous and subsequent periods is compared in real time, and the corresponding data is distributed and transmitted to the IoT communication module based on different input / output types (digital and analog). By performing data preprocessing locally, the edge computing module effectively reduces cloud computing pressure and data transmission bandwidth usage, improves the system's real-time response speed, and adapts to the low-latency operation requirements of IoT scenarios.

[0028] like Figure 1 As shown, the power management module includes three switching power supplies. These power supplies achieve DC isolation through a power conversion chip, providing 15V, 5V, 3.3V, and 1.8V DC power to each module. The 15V voltage is input to the MP2457GJ-Z DC-DC buck module, which converts it to 5V. The 5V voltage is then connected to the DA9080-61FCB2 voltage regulator chip, which regulates and outputs 3.3V and 1.8V respectively. The 3.3V voltage supplies power to the microcontroller unit, data storage unit, and other functional modules, while the 1.8V voltage provides a reference voltage for the microcontroller unit. This hierarchical isolation power supply architecture avoids power crosstalk between modules, ensuring stable system operation.

[0029] like Figure 1As shown, in terms of specific interface design, the digital input / output module includes digital input ports and digital output ports. The digital input ports connect to field switch signal devices, and the digital output ports connect to field actuator devices. The analog input / output module connects to analog sensors and actuators in the industrial field, acquiring ±20mA current signals and ±10V voltage signals.

[0030] like Figure 1 As shown, the mobile terminal connects to the cloud platform via a wireless network to complete two-way data interaction and configure the network connection parameters of the IoT communication module. The mobile terminal is equipped with a device configuration module, a data monitoring module, and a remote control module. The device configuration module is used to configure the network access of the IoT communication module, specifically supporting two configuration modes:

[0031] The first type is the wireless LAN (WLAN) configuration mode. In this mode, the mobile terminal scans for WiFi networks in the surrounding environment via Bluetooth or WiFi AP (Access Point) mode, and sends the user-entered WiFi name and corresponding password to the IoT (Internet of Things) communication module in the main control circuit board. After receiving the configuration parameters, the IoT communication module automatically switches to WiFi STA mode to access the designated wireless network. The second type is the cellular network configuration mode. In this mode, the mobile terminal directly configures the 4G APN (Access Point Provider) parameters to the IoT communication module, enabling the device to connect to the network via the 4G public network.

[0032] The data monitoring module displays the status information and real-time data of the I / O channels. The remote control module enables the issuance of operation commands to remote I / O systems.

[0033] During operation, the remote I / O system acquires data from field devices in real time via digital input / output (DIO) and analog input / output (AIO) modules. The acquired signals are processed by a microcontroller unit. The processed data can be used to directly control the output based on local logic, enabling rapid response at the edge. Simultaneously, it is reported to the cloud via an IoT communication module and then transmitted to a mobile terminal for display. It can also receive commands from the mobile terminal sent to the cloud, enabling reverse control of field actuators. When the network is interrupted, the acquired data is automatically saved to the data storage module and automatically retransmitted after the network is restored.

[0034] like Figure 2 As shown, a status indicator array 1 is also installed on the structural housing, which includes power indicator lights and I / O channel status indicator lights. By observing the status of the indicator lights, on-site maintenance personnel can intuitively judge the working status of the equipment, greatly facilitating on-site debugging and troubleshooting.

[0035] like Figure 3As shown, for easy on-site installation, the structural housing is equipped with guide rail clips 2. These guide rail clips 2 are standard guide rail clips, used to quickly and easily detach and install the remote I / O system onto standard guide rails inside the control cabinet. Disassembly and assembly can be completed without tools, greatly simplifying the on-site deployment process.

[0036] In summary, this utility model integrates a microcontroller unit, an IoT communication module, and an I / O interface into a single unit through integrated design, achieving efficient signal acquisition, wireless transmission, and remote control in industrial settings. Its edge computing capabilities reduce the burden on the cloud, while the offline transmission resume function enhances system reliability. Combined with mobile terminals for network configuration, data monitoring, and remote control, it further enhances the product's practicality and user experience. The inclusion of guide rail clips and status indicator lights simplifies on-site deployment, debugging, and maintenance.

[0037] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A remote I / O system with Internet of Things (IoT) functionality, comprising a structural housing, a main control circuit board disposed within the structural housing, and a mobile terminal, wherein the main control circuit board integrates an IoT communication module, a data storage module, a microcontroller unit, a power management module, a digital input / output module, and an analog input / output module; characterized in that, The microcontroller unit connects to each functional module via three independent buses: it is connected to the IoT communication module via the SPI bus, to the data storage module via the QSPI bus, and to the digital input / output module and analog input / output module via the RS485 bus; and it is electrically connected to the power management module via the power bus. The microcontroller unit has a built-in edge computing module, which is connected to the digital input / output module, analog input / output module, data storage module, and IoT communication module to form a data transmission link for IO signal acquisition, local preprocessing, data storage, and wireless transmission. The IoT communication module is a multi-mode converged communication module integrating Bluetooth, WiFi and 4G, supporting dual-mode interaction of local direct connection and remote network connection, and can connect to the cloud platform and local gateway to achieve bidirectional data transmission; The mobile terminal is connected to the IoT communication module via a wireless network.

2. The remote IO system with Internet of Things function according to claim 1, characterized in that, The data storage module uses AT25SF128A-SHB-T to store parameters and location data. It has Flash storage management function, which temporarily stores the collected IO data in Flash when the network is disconnected, and re-transmits the Flash-stored data to the cloud platform after the network is restored, and then transmits it to the mobile terminal for display.

3. The remote IO system with Internet of Things function according to claim 1, characterized in that, The edge computing module is used to perform local preprocessing on the collected IO data. The local preprocessing includes time filtering, PT range conversion, and threshold judgment. The time filtering uses a delay-based de-jitter filtering method to eliminate instantaneous interference in the acquired signal and improve the stability of the original IO data; the PT range conversion converts the original electrical signal of the sensor into a PT standard physical quantity; the threshold judgment synchronously performs data overflow detection and data underflow detection, and generates an abnormal alarm signal when the acquired value exceeds the preset upper and lower thresholds. At the same time, it compares the data change amplitude of the previous and subsequent periods in real time, and according to the different input and output types of digital and analog quantities, it diverts the corresponding classified data to the IoT communication module.

4. The remote IO system with Internet of Things function according to claim 1, characterized in that, The power management module includes three switching power supplies. These switching power supplies achieve DC isolation through a power conversion chip and provide 15V, 5V, 3.3V, and 1.8V DC power to each module. The 15V voltage serves as the input voltage of the MP2457GJ-ZDC-DC module, which outputs 5V after voltage conversion. The 5V voltage serves as the input voltage of the DA9080-61FCB2, which outputs 3.3V and 1.8V after regulation. The 3.3V power supply to the microcontroller and data storage module, while the 1.8V provides a reference voltage for the microcontroller.

5. The remote IO system with internet of things function according to claim 1, characterized in that, The digital input / output module includes a digital input port and a digital output port; the digital input port is connected to the field switch signal device, and the digital output port is connected to the field actuator device.

6. The remote IO system with internet of things function according to claim 1, characterized in that, The analog input / output module supports the input and output of ±20mA current signals and ±10V voltage signals, and can be connected to analog sensors and actuators in the industrial field.

7. The remote IO system with internet of things function of claim 1, wherein, The mobile terminal is used to configure the network connection parameters of the IoT communication module and to interact with the cloud platform; the mobile terminal includes: The device network configuration module supports both wireless LAN network configuration mode and cellular network configuration mode, and is used to configure the network access of the IoT communication module. The data monitoring module is used to display the status and data of the IO channel in real time; The remote control module is used to send control commands to the remote I / O system. 8.The remote IO system with Internet of Things function of claim 1, wherein, The structural housing is also provided with a status indicator array (1), which includes a power indicator and an IO channel status indicator.

9. The remote IO system with internet of things function of claim 1, wherein, The structural housing is provided with a guide rail clip (2), which is a standard DIN guide rail clip, used to detachably install the remote IO system on the standard guide rail inside the control cabinet.

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