A shuttle vehicle core controller

Abstract

The application relates to a shuttle vehicle core controller, which comprises a printed circuit board, the printed circuit board is divided into a first functional subarea, a second functional subarea and a third functional subarea; a signal input and output module is integrated in the first functional subarea, the signal input and output module comprises a plurality of wiring terminal groups arranged along the longitudinal direction of the printed circuit board; a network communication module is integrated in the second functional subarea, the network communication module comprises at least one Ethernet interface; a power module is integrated in the third functional subarea, the power module comprises a power terminal used for connecting an external power supply; a mounting and fixing module is arranged on the printed circuit board and used for fixing the core controller to an external device; wherein the signal input and output module, the network communication module, the power module and the mounting and fixing module are electrically connected and mechanically supported through wiring inside the printed circuit board, and form an integrated structure. The core controller is strong in anti-interference performance, compact in structure and reliable in connection.

Description

Technical Field

[0001] This application relates to the field of logistics and warehousing automation technology, and in particular to a core controller for a shuttle vehicle. Background Technology

[0002] In recent years, with the rapid development of e-commerce, manufacturing, cold chain and other industries, warehousing systems have placed higher demands on space utilization and operational efficiency. "High-density storage + automated storage and retrieval" has become the core direction of smart warehousing construction. As a key execution unit to achieve this goal, intelligent shuttle vehicles undertake important functions such as precise location of goods, efficient transfer of goods and collaborative operation of multiple devices. Their performance directly affects the throughput efficiency and operational reliability of the entire warehousing system.

[0003] Against this backdrop, the integration and reliability of control systems for automated storage and handling equipment, represented by four-way shuttles and encompassing AGVs and pallet shuttles, have become increasingly important technological focuses. However, traditional split-type controllers still have many limitations in practical applications, including large physical structure, low electrical connection reliability, loose inter-module layout, and insufficient resistance to electromagnetic interference. These issues restrict further improvement in the overall performance of the equipment and make it difficult to fully meet the demands of the modern intelligent logistics industry for efficient, stable, and flexible operation.

[0004] Therefore, there is an urgent need for an integrated shuttle core controller that is highly resistant to interference, has a compact structure, and is reliable in connection. Utility Model Content

[0005] Therefore, it is necessary to provide a shuttle core controller that is highly resistant to interference, has a compact structure, and is reliable in connection, in order to address the above-mentioned technical problems.

[0006] This application provides a shuttle core controller, including:

[0007] A printed circuit board, wherein the printed circuit board is divided into independent first functional partition, second functional partition and third functional partition;

[0008] A signal input / output module is integrated into the first functional partition of the printed circuit board, and the signal input / output module includes multiple terminal blocks arranged longitudinally along the printed circuit board;

[0009] A network communication module is integrated into the second functional partition of the printed circuit board, and the network communication module includes at least one Ethernet interface;

[0010] A power module is integrated into the third functional partition of the printed circuit board, and the power module includes a power terminal for connecting to an external power source.

[0011] A mounting and fixing module is installed on the printed circuit board for fixing the core controller to an external device;

[0012] The signal input / output module, the network communication module, the power supply module, and the mounting and fixing module are electrically connected and mechanically supported by the wiring inside the printed circuit board, forming an integrated structure.

[0013] In one embodiment, each of the plurality of terminal blocks includes a plurality of pluggable terminal pins arranged in a straight line, the plurality of terminal pins corresponding to the positive power supply terminal, the signal input terminal and the ground terminal respectively; the plurality of terminal blocks are arranged in parallel at equal intervals to form a standardized signal channel matrix.

[0014] In one embodiment, the printed circuit board is a multilayer circuit board structure, and the power circuit and signal circuit of the signal input / output module are wired on different layers of the printed circuit board.

[0015] In one embodiment, the at least one Ethernet interface of the network communication module has a recessed structure, and the housing portion of the Ethernet interface is embedded in the printed circuit board; the communication signal traces of the network communication module are configured as matched traces with a preset impedance value inside the printed circuit board.

[0016] In one embodiment, the width of the power supply terminal of the power supply module is greater than the width of the pin of the wiring terminal of the signal input / output module; a grounding isolation strip formed by copper plating is provided between the third functional partition and the first functional partition.

[0017] In one embodiment, the mounting and fixing module includes a plurality of mounting holes formed at the four corners of the printed circuit board, and a settling platform structure is formed within a predetermined range around the mounting holes, the settling platform structure being used to accommodate the head of the fixing screw.

[0018] In one embodiment, the mounting and fixing module further includes a positioning structure disposed on the edge of the printed circuit board. The positioning structure includes a raised positioning post or a recessed slot, and the positioning structure is used to cooperate with the cabinet rail of the external device.

[0019] In one embodiment, the printed circuit board further includes a separate fourth functional partition, and the core controller also integrates a control core module arranged in the fourth functional partition; the control core module includes an embedded processing chip, which is electrically connected to the signal input / output module, the network communication module and the power supply module through traces inside the printed circuit board.

[0020] In one embodiment, the core controller also integrates a sensing module, which is electrically connected to the control core module. The sensing module is used to collect motor encoder signals and transmit them to the control core module.

[0021] In one embodiment, the signal input / output module forms an electrical isolation barrier between the input side and the output side of the signal input / output module through optical coupling isolation.

[0022] The aforementioned shuttle's core controller constructs an effective electrical isolation barrier by strictly separating the high-current power supply, sensitive signal processing, and high-speed communication modules into independent functional zones on a printed circuit board, combined with precise internal wiring. This design blocks power supply noise from interfering with signal acquisition and communication links at the source, ensuring the accuracy of signal transmission and the stability of communication data. Simultaneously, this solution significantly improves structural compactness by highly integrating each functional module onto a single printed circuit board and replacing traditional external cables with on-board wiring. This not only effectively reduces the controller's size but also fundamentally eliminates connection failures caused by loose external wiring, significantly enhancing the system's structural reliability and environmental adaptability. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or related technologies, the drawings used in the description of the embodiments of this application or related technologies will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the module structure of the shuttle core controller in one embodiment. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0026] It should be noted that the terms "first," "second," etc., used in this application can be used to describe various elements, but these elements are not limited by these terms. These terms are only used to distinguish the first element from the second element. The terms "comprising" and "having," and any variations thereof, used in this application, are intended to cover non-exclusive inclusion. The term "multiple" used in this application refers to two or more. The term "and / or" used in this application refers to one of the embodiments, or any combination of multiple embodiments.

[0027] In one exemplary embodiment, such as Figure 1 As shown, a shuttle core controller is provided, including:

[0028] The printed circuit board is divided into independent first functional zones, second functional zones, and third functional zones.

[0029] The signal input / output module is integrated into the first functional area of ​​the printed circuit board. The signal input / output module includes multiple terminal blocks arranged longitudinally along the printed circuit board.

[0030] A network communication module is integrated into the second functional partition of the printed circuit board, and the network communication module includes at least one Ethernet interface.

[0031] The power module is integrated into the third functional area of ​​the printed circuit board. The power module includes power terminals for connecting to an external power source.

[0032] Mounting and fixing modules, located on printed circuit boards, are used to fix the core controller to external devices;

[0033] The signal input / output module, network communication module, power supply module, and mounting module are electrically connected and mechanically supported by wiring inside the printed circuit board, forming an integrated structure.

[0034] Specifically, the first functional zone, the second functional zone, and the third functional zone are arranged in a vertical or horizontal strip on the printed circuit board. The zones are electrically interconnected through a pre-defined wiring path inside the printed circuit board without external cables, and are mechanically supported and fixed by the printed circuit board substrate itself.

[0035] The power module receives a 24V input voltage and generates multiple levels of adaptable voltages such as 3.3V and 5V through an isolation conversion circuit. While achieving electrical isolation and preventing interference, it provides stable and reliable power support for the entire system modules, including the control core, sensing, and communication modules.

[0036] The signal input / output module uses optocoupler isolation technology to build a signal transmission barrier. On the one hand, it safely receives the status signals from the photoelectric sensor and uploads them to the control core. On the other hand, it isolates and outputs the execution commands generated by the control core to the actuator, effectively avoiding the impact of external high voltage or electromagnetic interference on system stability.

[0037] The network communication module supports multi-protocol compatibility, and builds a channel for control command interaction with sub-modules (drivers), task data transmission with the upper-layer WCS system, and status information exchange with third-party devices, realizing bidirectional data flow and collaboration in all dimensions.

[0038] In this embodiment, by partitioning and integrating the core functional modules onto a single printed circuit board, an integrated structure without external connection cables is constructed, fundamentally eliminating the potential for failure caused by unreliable external cable connections and loose layout. At the same time, the overall size of the controller is significantly reduced, improving space utilization and structural reliability.

[0039] In one embodiment, each of the multiple terminal blocks includes multiple pluggable terminal pins arranged in a straight line, with the multiple terminal pins corresponding to the positive power supply, the signal input terminal, and the ground terminal, respectively; the multiple terminal blocks are arranged in parallel with equal spacing to form a standardized signal channel matrix.

[0040] Specifically, 30 independent terminal blocks (numbered 1-30) can be arranged longitudinally along the circuit board. The pluggable terminal pins can be three-pin structures, corresponding to the 24V power supply terminal, the signal input (IN) terminal, and the GND ground terminal in sequence. Multiple terminal block groups are arranged at equal intervals longitudinally along the printed circuit board, and the "24V-IN-GND" pins in each group are aligned in a straight line to form a standardized signal channel matrix. The bottom of the terminal is fixed to the PCB pad by soldering. The power circuit and signal circuit are isolated by layered routing between PCB layers (the functional zoning of the routing area is visible externally), and the central axes of the three pins in each group are collinear, forming a regular parallel signal channel.

[0041] In this embodiment, the standardized, matrix-style terminal layout makes the insertion and connection of external wiring harnesses more convenient and orderly, significantly improving on-site wiring efficiency and effectively reducing the risk of misconnection or mixed connection due to misaligned pins or inconsistent spacing, thus ensuring the accuracy of signal connections. Experimental data shows that compared to traditional irregular terminal layouts, the standardized grouping and alignment structure improves wiring harness efficiency by 40% and reduces the risk of misconnection / mixed connection by 90%. The layered wiring isolation structure blocks the transmission of 24V power supply noise to the IN / GND weak current signals, reducing signal acquisition errors.

[0042] In one embodiment, the printed circuit board has a multilayer circuit board structure, and the power circuit and signal circuit of the signal input / output module are wired on different layers of the printed circuit board.

[0043] Specifically, the power circuit is located on a dedicated power layer or a wider trace layer of the printed circuit board, while the signal circuit is located on an adjacent signal layer. The two are naturally isolated from each other through the dielectric layer and reference ground layer of the printed circuit board.

[0044] In this embodiment, the layered wiring characteristics of the multilayer board are utilized to achieve physical isolation between high power supply current and weak signal current, effectively blocking power supply noise from interfering with sensitive signal circuits through common impedance or electromagnetic coupling, thereby significantly improving the accuracy of signal acquisition and the system's anti-interference capability.

[0045] In one embodiment, at least one Ethernet interface of the network communication module is a recessed structure, with the housing portion of the Ethernet interface embedded within a printed circuit board; the communication signal traces of the network communication module are configured as matched traces with a preset impedance value inside the printed circuit board.

[0046] For example, the top of the circuit board is equipped with two RJ45 Ethernet interfaces, which adopt a recessed design (embedded in the PCB to reduce the overall height of the device); two sets of LED indicator solder points are provided next to the interfaces for visualization of link status / data transmission and reception; the network signal traces are impedance matched within the PCB (visible traces with equal length / equal spacing design) to reduce signal reflection.

[0047] Specifically, the recessed structure ensures that the top of the metal casing of the Ethernet interface is no higher than the height of adjacent components on the printed circuit board surface; the matching traces control the trace width, the spacing between the trace and the reference layer, and the dielectric material to match their characteristic impedance with the standard impedance of the communication protocol.

[0048] In this embodiment, the recessed plate structure reduces the overall installation thickness of the controller, enhancing its adaptability in compact spaces; at the same time, the impedance-matched wiring design minimizes reflection and distortion of high-speed communication signals during transmission, ensuring the stability and reliability of data communication.

[0049] In one embodiment, the width of the power supply terminal of the power supply module is greater than the width of the pin of the wiring terminal of the signal input / output module; a grounding isolation strip formed by copper plating is provided between the third functional partition and the first functional partition.

[0050] Specifically, the power supply terminal is a high-current power supply terminal suitable for transmitting ampere-level current; the ground isolation strip is a rectangular copper-clad area on the surface or bottom layer of the printed circuit board, which is connected to the system grounding network through vias, physically separating the third functional zone from the first functional zone.

[0051] For example, the bottom of the circuit board has multiple sets of high-current power terminals (marked with "H3 / L3 / 0", "CAN", "A1 / B1", etc.), with the terminal width being more than twice that of the signal terminals, supporting dual 24V redundant power supply; the power terminals and signal terminals are arranged in a spatial partition (the power terminals are concentrated at the bottom, and the signal terminals are concentrated in the middle), with a large area of ​​grounding copper strip in the middle (copper foil is visible on the bottom of the PCB).

[0052] In this embodiment, the wide-body power terminals meet the current-carrying requirements of high-current transmission and reduce contact resistance and heat generation; while the grounding isolation strip set between the power and signal partitions constitutes an effective electromagnetic shielding barrier, further absorbing electromagnetic radiation noise in the power area and enhancing the anti-interference effect of the partition layout.

[0053] In one embodiment, the mounting and fixing module includes a plurality of mounting holes formed at the four corners of the printed circuit board, and a settling platform structure is formed within a predetermined range around the mounting holes. The settling platform structure is used to accommodate the head of the fixing screw.

[0054] Specifically, the settling platform structure is an annular groove surrounding the mounting hole, with a depth adapted to the thickness of the screw head, and its diameter is larger than the mounting hole diameter.

[0055] For example, φ5mm circular mounting holes are provided at the four corners (with φ6mm settlement platforms around the holes to accommodate M4 screw heads); positioning posts / slots are provided at the edges (protrusions / grooves are visible on the left / right edges) to precisely match the equipment cabinet rails.

[0056] In this embodiment, the settling platform structure allows the head of the fixing screw to be embedded inside the printed circuit board, avoiding installation interference caused by the screw head protruding, realizing flat installation of the controller, reducing the overall installation thickness, and improving the convenience and stability of installation.

[0057] In one embodiment, the mounting and fixing module further includes a positioning structure disposed on the edge of the printed circuit board. The positioning structure includes a raised positioning post or a recessed slot, and the positioning structure is used to cooperate with the cabinet rail of the external device.

[0058] Specifically, the positioning post is a cylindrical protrusion, and the slot is a rectangular or circular groove that matches the shape of the positioning post. The positioning structure is inserted or engaged with the corresponding structure on the rack rail.

[0059] In this embodiment, the positioning column and the slot work together to achieve pre-positioning and quick alignment of the controller before the screws are tightened, ensuring accurate installation and greatly simplifying the installation process in a standardized cabinet, thus improving installation efficiency and accuracy.

[0060] In one embodiment, the printed circuit board further includes a separate fourth functional partition, and the core controller also integrates a control core module arranged in the fourth functional partition; the control core module includes an embedded processing chip, which is electrically connected to the signal input / output module, the network communication module and the power supply module through traces inside the printed circuit board.

[0061] Specifically, the control core module, as the central hub of the system, is responsible for parsing upper-layer WCS task instructions, processing data such as motor speed / position collected by the sensor modules, generating precise logic control signals, and coordinating the collaborative operation of various modules. It is the core execution unit for the control function of the entire system. The embedded processing chip is connected to each module through the address bus, data bus, and control bus inside the printed circuit board.

[0062] In this embodiment, by adding an independent control core partition and integrating the system centralization into it, the control function is centralized and modularized, the signal path between functional units is shortened, the signal processing speed and system response efficiency are improved, and the unified management and maintenance of control logic is facilitated.

[0063] In one embodiment, the core controller also integrates a sensing module, which is electrically connected to the control core module. The sensing module is used to collect motor encoder signals and transmit them to the control core module.

[0064] Specifically, the sensing module includes an encoder signal processing circuit, whose input is connected to the motor encoder, and whose output transmits the processed position or speed signal to the corresponding input interface of the control core module. The sensing module uses the motor encoder as its core detection component, dynamically capturing the speed changes and real-time position parameters of the moving motor. Combined with MCU output commands, this directly affects the shuttle's motion control, ensuring the precise execution of the running trajectory and start / stop actions.

[0065] In this embodiment, the sensing module is directly integrated into the controller, which shortens the transmission path of high-frequency, weak encoder signals and reduces the risk of signal interference in long-distance external lines. This improves the real-time performance and accuracy of motion control feedback signals, ensuring the precise positioning and smooth operation of the shuttle.

[0066] In one embodiment, the signal input / output module forms an electrical isolation barrier between the input side and the output side of the signal input / output module through optical coupling isolation.

[0067] An optocoupler is installed between the input and output circuits of the signal input / output module. The electrical signal on the input side drives the light-emitting diode, and the phototransistor on the output side receives the optical signal and reconstructs the electrical signal, thus achieving physical isolation between the electrical components.

[0068] In this embodiment, optocoupler isolation technology is used to construct an electrical safety barrier inside the controller, which can effectively block interference such as high voltage and surge current from the external field from entering the core circuit of the controller through the I / O channel, greatly enhancing the reliability and robustness of the system in complex industrial environments.

[0069] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this application.

[0070] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A core controller for a shuttle vehicle, characterized in that, The shuttle's core controller includes: A printed circuit board, wherein the printed circuit board is divided into independent first functional partition, second functional partition and third functional partition; A signal input / output module is integrated into the first functional partition of the printed circuit board, and the signal input / output module includes multiple terminal blocks arranged longitudinally along the printed circuit board; A network communication module is integrated into the second functional partition of the printed circuit board, and the network communication module includes at least one Ethernet interface; A power module is integrated into the third functional partition of the printed circuit board, and the power module includes a power terminal for connecting to an external power source. A mounting and fixing module is installed on the printed circuit board for fixing the core controller to an external device; The signal input / output module, the network communication module, the power supply module, and the mounting and fixing module are electrically connected and mechanically supported by the wiring inside the printed circuit board, forming an integrated structure.

2. The shuttle core controller according to claim 1, characterized in that, Each of the multiple terminal blocks includes multiple pluggable terminal pins arranged in a straight line, with the multiple terminal pins corresponding to the positive power supply, signal input terminal, and ground terminal, respectively; the multiple terminal blocks are arranged in parallel with equal spacing to form a standardized signal channel matrix.

3. The shuttle core controller according to claim 1, characterized in that, The printed circuit board has a multilayer circuit board structure, and the power circuit and signal circuit of the signal input / output module are wired on different layers of the printed circuit board.

4. The shuttle core controller according to claim 1, characterized in that, The at least one Ethernet interface of the network communication module has a recessed structure, and the housing of the Ethernet interface is embedded in the printed circuit board; the communication signal traces of the network communication module are constructed as matched traces with a preset impedance value inside the printed circuit board.

5. The shuttle core controller according to claim 1, characterized in that, The width of the power supply terminal of the power supply module is greater than the width of the pin of the wiring terminal of the signal input / output module; a grounding isolation strip formed by copper plating is provided between the third functional partition and the first functional partition.

6. The shuttle core controller according to claim 1, characterized in that, The mounting and fixing module includes multiple mounting holes formed at the four corners of the printed circuit board. A settling platform structure is formed within a preset range around the mounting holes. The settling platform structure is used to accommodate the head of the fixing screw.

7. The shuttle core controller according to claim 1, characterized in that, The mounting and fixing module also includes a positioning structure disposed on the edge of the printed circuit board. The positioning structure includes a protruding positioning post or a recessed slot, and the positioning structure is used to cooperate with the cabinet rail of the external equipment.

8. The shuttle core controller according to claim 1, characterized in that, The printed circuit board also includes an independent fourth functional partition, and the core controller integrates a control core module arranged in the fourth functional partition; the control core module includes an embedded processing chip, which is electrically connected to the signal input / output module, the network communication module and the power supply module through traces inside the printed circuit board.

9. The shuttle core controller according to claim 8, characterized in that, The core controller also integrates a sensing module, which is electrically connected to the control core module. The sensing module is used to collect motor encoder signals and transmit them to the control core module.

10. The shuttle core controller according to claim 1, characterized in that, The signal input / output module forms an electrical isolation barrier between its input and output sides through optical coupling isolation.

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