A combined controller

Abstract

The utility model provides a kind of combined controller, the controller includes shell assembly, shell assembly includes upper cover, lower cover and pcb board, upper cover is equipped with buckle structure, for embedding type installation of controller on panel with hole, lower cover is equipped with special interface, for with the special interface connection of alternating current contactor, pcb board is equipped with control component, indicating component and function component, upper cover is equipped with through-hole, for accommodating control component and indicating component pass through;The utility model reduces the secondary loop wiring complexity and quantity of traditional control cabinet by the design of high integration, integrates alternating current contactor control, signal acquisition, logic operation, state indication and man-machine interaction etc. Function in single device, directly plugs with alternating current contactor through special interface, saves a lot of control and feedback connection between the two.

Description

Technical Field

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

[0002] In the field of industrial automation control, traditional control systems are usually composed of discrete components such as circuit breakers, contactors, relays, buttons and indicator lights, which are combined through complex secondary circuit wiring to achieve basic logic control and motor drive functions. Such systems are widely used in the start-up, stop and switching control of equipment such as fans, pumps and compressors.

[0003] Traditional control schemes require a large number of wires for complex hard-wiring connections in the secondary circuit. This not only consumes a lot of raw materials such as wires and terminals, but also requires a lot of manpower for installation, commissioning and subsequent maintenance. The wiring process is cumbersome and prone to errors. At the same time, the system has low integration, occupies a large cabinet space, and has poor flexibility and scalability, making it difficult to meet the requirements of modern industry for compact, intelligent and rapid deployment of equipment.

[0004] Therefore, in response to the problems of complex wiring and high cost of traditional control cabinets, this utility model proposes a combined controller, which integrates control logic, interface and execution unit into one unit, thereby reducing the number of external secondary circuits and thus saving installation materials and labor costs. Utility Model Content

[0005] To overcome the problems of complex wiring and high cost of traditional control cabinets, this utility model proposes a combined controller.

[0006] The technical solution of this utility model is as follows: a combined controller, including a housing assembly, the housing assembly including an upper cover, a lower cover and a PCB board, the upper cover having a snap-fit ​​structure for embedding the controller on a panel with holes, the lower cover having a dedicated interface for connecting to a dedicated interface of an AC contactor, the PCB board having a control component, an indicator component and a functional component, and the upper cover having a through hole for accommodating the control component and the indicator component to pass through. The functional components include a transmission module, a processing module, and a power supply module.

[0007] Preferably, the controller is embedded and installed on the panel using an integrated clip and screws on the upper cover. The dedicated interface on the lower cover directly connects to the dedicated interface of the AC contactor, completing the mechanical and electrical connection. After power is connected, the power module supplies power to the MCU chip, indicator lights, relays, and other electronic components. Users can connect to the controller via wired or wireless terminals (such as computers or mobile apps) to set parameters (such as timing and delay lengths) and write logic programs (such as logic for motor start / stop, liquid level judgment, and fault handling). The program is then downloaded to the MCU chip. After the controller is put into operation, the MCU chip continuously monitors the input through the terminals. Digital signals (such as start / stop buttons, high / low level switch status) and analog signals (such as temperature and pressure sensor readings) are processed by the MCU chip according to a preset logic program (such as performing timing, delay, and logic judgment functions). The MCU then drives the relays on the PCB board to operate. The on / off state of the relay contacts controls the output circuit, which in turn sends control signals to external devices such as AC contactors through terminals. This ultimately achieves various control functions such as single motor start / stop, dual motor sequential start, automatic liquid level pump control, and motor star-delta conversion. The operating status is displayed in real time by indicator lights on the PCB board, and users can remotely monitor the system through a terminal.

[0008] Preferably, the control component includes buttons for manual operation or parameter setting.

[0009] Preferably, the indicating component includes indicator lights for displaying the controller's operating status or signal feedback.

[0010] Preferably, the transmission module includes terminals for connecting power signals, digital input / output signals, analog input / output signals, and communication signals.

[0011] Preferably, the processing module also includes an MCU chip for executing logic programs, processing input signals, and outputting control commands.

[0012] Preferably, the power supply module also includes a power module and a relay fixed to the PCB board.

[0013] Preferably, the snap-fit ​​structure includes a snap-fit, with the top cover snap-fit ​​being fixedly connected to the housing in one piece. The snap-fit ​​has a screw mounting hole inside, which is used for embedded mounting on a panel with holes by using a mounting screw controller.

[0014] Preferably, the snap-fit ​​structure includes a fixing component and a mounting component, with the fixing component fixed to the panel and the mounting component fixed to both sides of the top cover.

[0015] Preferably, the fixing component includes a fixing block and a movable component movably connected within the fixing block, and the mounting component includes a slider with a slot adapted to the movable component for accommodating the movable component and locking the mounting component in place.

[0016] Preferably, the movable component includes a locking block movably connected within the fixed block, a connecting rod fixed to the locking block, a spring fixed within the fixed block, and a pull plate fixed to the other side of the connecting rod, for locking the slider within the fixed block.

[0017] The beneficial effects of this utility model are: 1. The highly integrated design reduces the complexity and quantity of secondary circuit wiring in traditional control cabinets. It integrates functions such as AC contactor control, signal acquisition, logic operation, status indication, and human-machine interaction into a single device. It can be directly plugged into the AC contactor through a dedicated interface, eliminating a large number of control and feedback connections between the two. At the same time, the integrated terminal block design simplifies the connection of external sensors and actuators, greatly reducing the consumption of materials such as cables, terminal crimping connectors, and wire gauges in the cabinet, thus reducing material costs.

[0018] 2. Adopting an integrated structure and panel-embedded installation method, the installation process is quick and easy by combining pre-fixing with buckle and screw locking. This avoids the cumbersome wiring work of arranging, fixing and connecting multiple discrete components on DIN rails in traditional solutions, which greatly shortens the assembly time of the distribution cabinet and thus effectively saves labor costs. Attached Figure Description

[0019] Figure 1 The diagram shown is a three-dimensional structural schematic of the present invention. Figure 2 The diagram shown is a structural schematic of the present utility model and its panel mounting. Figure 3 The diagram shown is a schematic representation of the upper cover structure of this utility model. Figure 4 The diagram shown is a schematic representation of the snap-fit ​​structure of this utility model. Figure 5 The diagram shown is a cross-sectional view of the snap-fit ​​structure of this utility model.

[0020] Explanation of reference numerals in the attached diagram: 1. Top cover; 2. Bottom cover; 3. PCB board; 4. Buckle; 5. Fixing block; 6. Slider; 7. Slot; 8. Block; 9. Connecting rod; 10. Spring; 11. Pull plate. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the protection scope of this utility model.

[0022] Please see Figure 1 and Figure 2 This utility model provides an embodiment of a combined controller: This utility model includes an upper cover 1, a lower cover 2, and a PCB board 3 encapsulated inside them.

[0023] Furthermore, the bottom of the lower cover 2 is equipped with a dedicated interface. This interface integrates the mechanical structure and electrical interface. The shape, size, and pin definition of this interface are compatible with the top auxiliary contact interface or dedicated control interface of commonly used AC contactors (such as Chint NCH8 series, Delixi CJX2s series, etc.). This allows for blind-plug alignment. During installation, simply align the controller's dedicated interface with the corresponding interface on the top of the AC contactor and press down to complete the mechanical locking and electrical connection, thus eliminating the need for traditional DIN rails or screw installation.

[0024] Furthermore, the upper surface of the top cover 1 is provided with multiple through holes. The positions of these through holes correspond one-to-one with the positions of the indicator lights and buttons (such as emergency stop, start, stop, reset and other self-reset buttons) soldered on the PCB board 3. This allows the status indication and manual operation functions to be retained and integrated into the controller body, eliminating the need for an external independent button box and further reducing external wiring and installation procedures.

[0025] Furthermore, the top cover 1 has clips 4 around its four edges, each clip 4 having a pre-drilled screw mounting hole. During installation, simply place the controller into the pre-drilled square hole on the distribution cabinet panel and push it inward from the front of the panel. The clip will spring back after elastic deformation, thus initially securing the controller to the panel. Then, use a screwdriver to screw the screws into the screw mounting holes on the clips until the bottom of the screws is flush against the back of the panel, thus achieving a secure embedded installation. Compared to traditional panel installation, which requires the combination of multiple discrete components for installation and fixation, this installation method greatly improves installation efficiency. The processing adopts one-piece molding, reducing processing steps and components. Traditionally, at least three components are required to complete the installation, but now only one is needed.

[0026] Furthermore, the upper cover 1 has a snap-fit ​​structure around its four edges, including a fixing component and an installation component. The fixing component is fixed to the panel, and the installation component is fixed to both sides of the upper cover. The fixing component further includes a fixing block and a movable component movably connected within the fixing block. The installation component includes a slider 6, which has a slot 7 adapted to the movable component for accommodating the movable component and clamping the installation component during installation. The movable component specifically includes a clip 8 movably connected within the fixing block, a connecting rod 9 fixed to the clip block, a spring 10 fixed within the fixing block, and a pull plate 11 fixed to the other side of the connecting rod. By pulling the pull plate 11, the clip 8 can compress the spring 10 and disengage from the slot 7. After releasing the pull plate 11, the spring 10 rebounds and pushes the clip 8 into the slot 7, thereby firmly clamping the slider 6 within the fixing block 5, realizing the quick installation and disassembly of the controller.

[0027] Furthermore, PCB board 3 includes electronic components such as terminals, indicator lights, buttons, MCU chips, power supplies, and relays. The terminals can connect to power supplies, digital input and output signals, analog input and output signals, and communication signals. Specifically: The terminal is located on edge 3 of the PCB board and is used to connect all external signals. It includes: The power terminals (L, N, PE) are used to connect the controller's operating power supply (such as AC 220V or DC 24V).

[0028] Digital input terminals (such as DI1~DI6) are used to receive external switching signals, such as passive dry contact signals from devices like emergency stop buttons, rotary switches, level floats, pressure relays, and limit switches.

[0029] Digital output terminals (such as DO1~DO4) are used to output switching control signals. In addition to controlling the main AC contactor through a dedicated interface, they can also directly drive some low-power intermediate relays.

[0030] The analog input terminals (such as AI1, AI2) can receive continuously changing signals from sensors (such as temperature sensor PT100, pressure transmitter 0-10V, level transmitter 4-20mA).

[0031] The communication interface terminal (COM) supports industrial bus protocols such as RS-485 Modbus RTU and can be used to connect to host computers (such as PLC, HMI, SCADA systems) to achieve remote monitoring and parameter configuration.

[0032] The MCU chip is an industrial-grade microcontroller based on the ARM Cortex-M core. It is responsible for executing the logic control program written by the user, processing all input signals, performing logic operations, timing, counting and comparison, and driving the corresponding output according to the operation results.

[0033] The relay includes at least one relay for controlling the coil of an AC contactor, the output of which is directly connected to the control pin of the dedicated interface.

[0034] The power module is used to supply power to various units.

[0035] Wireless communication modules, such as Wi-Fi, Bluetooth, or cellular communication modules, enable wireless connections via mobile terminals such as smartphones and tablets, allowing for parameter setting, logic program downloading, and monitoring of operational status.

[0036] Through the examples, it is found that in traditional solutions, a simple motor start-stop control requires at least 7-15 wires (2 power supply wires, 2 coil control wires, 3-5 button wires, 2-4 indicator light wires, and 2-6 feedback wires), resulting in a large consumption of cables, wire gauges, and terminal crimping connectors. However, in this detailed utility model, the control of the AC contactor is directly connected through a dedicated interface, shortening the wiring length. The number of wires used for buttons and indicator lights is zero. External sensors and buttons only require two cables to connect to the controller terminal block, which greatly reduces the amount, types, and length of cables used in the cabinet and eliminates a large number of intermediate wiring terminals. This also eliminates a lot of secondary wiring work in the cabinet between relays and contactors, and between relays and buttons. Wiring is simplified to simply connecting external cables to the controller terminal blocks, significantly reducing workload. Traditional DIN rail mounting of multiple components and individual wiring is time-consuming; this solution embeds a single controller unit, standardizing and simplifying the installation process for maximum efficiency. Furthermore, due to the built-in logic, technicians no longer need to sift through complex schematics and wiring harnesses to troubleshoot; they can quickly diagnose, modify parameters, and even update programs via wired or wireless connections. Additionally, the device uses pluggable terminals, making future replacements and maintenance much easier and faster. Furthermore, this utility model provides an embodiment for describing the start-stop control of a single motor: Please refer to Table 1. This embodiment uses the most common three-phase asynchronous motor direct start control as an example for explanation.

[0037] The traditional solution requires the assembly of one circuit breaker, one AC contactor, one thermal overload relay, one emergency stop button, one start button, one stop button, one running indicator light, and one fault indicator light. The secondary circuit inside the cabinet requires approximately 25-30 wires to connect the above components and approximately 40 terminals. It takes a skilled electrician about 1-1.5 hours to complete all the wiring and inspection.

[0038] In this embodiment, the system requires only one circuit breaker, one AC contactor, and this combined controller. During installation, the controller is first embedded into the predetermined holes in the cabinet panel using the integrated clips and screws on its upper cover 1. Then, the dedicated interface on the lower cover 2 of the controller is aligned with the corresponding interface on the top of the AC contactor and directly plugged in, thus completing the mechanical locking and electrical connection in one step. This process eliminates all secondary wiring between the control element and the contactor. Because a fixed connection is used, the length of the wires is essentially fixed, allowing for the use of mass-produced wires, further reducing installation time and cost; and it also enables automated assembly. The specific wiring operation only involves connecting the main circuit power line to the circuit breaker in the conventional way and connecting it to the motor through the contactor's main contacts. Connect the lead of the external feedback contact to the digital input DI1 terminal of the controller, and connect the lead of the fault contact to the digital input DI2 terminal of the controller. (The purpose of the DI point can be determined by customization, and the controller can perform logical judgment and output control through the input signal of DI.) Finally, connect the external 220V working power supply lead to the L and N power input terminals of the controller. At this point, all wiring is completed, and there is no need to connect any wires separately for the contactor coil, indicator lights, etc.

[0039] The logic configuration is connected to the controller's wireless communication module via a wireless method (such as a mobile APP). A simple start-stop program can be written using the built-in graphical logic editor. Its logic can be set to drive the digital output DO1 to conduct and form a self-lock when the emergency stop signal is invalid and a start signal is detected. It will not be disconnected until a stop signal or fault signal is received. At the same time, it can be set to light up the integrated operation indicator on the controller body when the DO1 output is ON to provide local status indication.

[0040] The number of wires used in the secondary circuit has been drastically reduced from about 30 to only 6 (2 DI wires, 2 power wires and 2 DO wires), saving more than 85% of resources. The number of terminals used has been reduced from about 40 to 4 positions on the controller terminal block, saving more than 90% of resources. The corresponding wiring and debugging time has also been greatly shortened from the traditional 1.5 hours to about 0.3 hours, improving efficiency by more than 80%.

[0041] Table 1. Single motor start-stop control effect

[0042] Please refer to Table 2. Furthermore, this utility model provides an embodiment for describing the sequential start control of dual motors: In traditional dual-motor sequential start control schemes, to achieve the function of starting one motor first and delaying the start of another, an additional set of AC contactors, thermal relays, and a dedicated time relay are required on top of the components needed for single-motor control (circuit breakers, contactors, thermal relays, buttons, indicator lights). This significantly increases the number of components in the entire control system, and the secondary circuits inside the cabinet become extremely complex. The coils and contacts of the time relays need to be connected to the coils, auxiliary contacts, and buttons of the two contactors according to logical relationships through various wires. Typically, about 50 wires and about 60 terminals need to be laid. It takes at least 2 hours for a skilled electrician to complete such complex wiring, inspection, and debugging work, which not only consumes a lot of wires and terminals but also incurs extremely high labor costs.

[0043] With the combined controller of this utility model, the dual-motor sequential start control system only needs to retain two AC contactors for main circuit switching and one controller. During installation, if the controller has multiple dedicated interfaces, two contactors can be directly plugged in. If there is only one dedicated interface, the output controlling the second motor can be connected to the coil of the second contactor through another digital output terminal (DO) of the controller. At the same time, the cables of the start and stop buttons are connected to the digital input (DI) terminal of the controller and connected to the working power supply. This completes all hardware installation and wiring, completely eliminating the time relay and its complex interlocking and delay control circuit between the two contactors that are indispensable in the traditional solution.

[0044] After the hardware installation and wiring are completed, the controller can be connected via a wired or wireless terminal (such as a mobile APP). The control logic can be easily set using its built-in graphical logic programming software. For example, a simple program can be written: when a start signal is received, the first output (DO1) is immediately driven to start the first motor, and a timer (TON Timer1) with a set value of 10 seconds is triggered to start counting. When the timer reaches its countdown, its completed (Done) bit becomes true, thereby driving the second output (DO2) to start the second motor automatically. When a stop signal is received, both outputs are turned off at the same time. All complex delay and sequential logic is flexibly implemented through the software program without any hardware circuit changes.

[0045] In terms of secondary circuits, the traditional solution requires approximately 50 control cables and 60 terminals, which is reduced to only a few wires for connecting buttons and possibly a second contactor, as well as a small number of terminals for the controller itself, resulting in savings of over 80%. In terms of manpower, the traditional tedious wiring and debugging work of about 2 hours is shortened to a simple wiring and program download process of less than half an hour, improving efficiency by over 75%. This not only significantly reduces material costs and cabinet space usage, but also greatly reduces reliance on manpower and the risk of malfunctions caused by wiring errors.

[0046] Table 2. Effect of Dual-Motor Sequential Start-up Control

[0047] Furthermore, this utility model provides an embodiment for automatic liquid level control: In traditional automatic liquid level control schemes, in order to enable the water pump to automatically start and stop according to the liquid level and display the liquid level value, it is usually necessary to use a logic control circuit composed of multiple relays and time relays to process the high and low liquid level switch signals. At the same time, it is also necessary to equip an independent digital display or analog input module to connect and display the continuous signal from the analog liquid level sensor. This combination of discrete components not only leads to a large number of required components and an increased control cabinet size, but also makes the wiring of the secondary circuit inside the cabinet extremely complex, introducing too many connection points and potential failure risks.

[0048] In this embodiment, all hardware wiring can be completed simply by connecting the normally closed contact signal line of the high-level liquid level switch to the digital input DI3 terminal of the controller, the normally open contact signal line of the low-level liquid level switch to the digital input DI4 terminal, the 4-20mA current signal line output by the analog liquid level sensor to the analog input AI1 terminal of the controller, and finally the command line of the AC contactor coil controlling the main circuit of the water pump to the digital output DO1 terminal of the controller.

[0049] In terms of program settings, users can use a graphical logic editor via wired or wireless terminals to write control logic. For example, when the liquid level is below the low limit (DI4 is on) and there is no fault signal in the system, the controller will drive DO1 to output ON to start the water pump, and when the liquid level is above the high limit (DI3 is off), the controller will drive DO1 to output OFF to stop the water pump. It can also be programmed to upload the real-time liquid level value collected by AI1 to the host computer HMI for centralized display via the communication interface, or use the LED indicator integrated on the controller to indicate the current water pump operating status or system fault status.

[0050] This embodiment highly integrates the complex system that traditionally relies on relay logic and independent display instruments into a single controller. By replacing most of the hardware wiring logic with programmable software logic, it not only greatly simplifies the cabinet layout and secondary wiring, but also saves a lot of materials such as wires and terminals, as well as labor costs for installation, debugging and subsequent maintenance.

[0051] The above are merely preferred embodiments of this utility model and are not intended to limit the utility model in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments for application in other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of this utility model without departing from the technical solution of this utility model shall still fall within the protection scope of this utility model.

Claims

1. A combined controller, characterized in that: It includes a housing assembly, which includes an upper cover (1), a lower cover (2) and a PCB board (3). The upper cover (1) has a snap-fit ​​structure for embedding the controller onto a panel with holes. The lower cover (2) has a dedicated interface for connecting to a dedicated interface of an AC contactor. The PCB board (3) has control components, indicator components and functional components. The upper cover (1) has a through hole for accommodating the control components and indicator components. The functional components include a transmission module, a processing module, and a power supply module.

2. The combined controller according to claim 1, characterized in that: The control components include buttons fixed to the PCB board for manual operation or parameter setting.

3. A combined controller according to claim 1, characterized in that: The indicator components include indicator lights fixed to the PCB board for displaying the controller's operating status or signal feedback.

4. A combined controller according to claim 1, characterized in that: The transmission module includes terminals fixed to the PCB board for connecting power signals, digital input / output signals, analog input / output signals, wired communication signals, and wireless communication signals.

5. A combined controller according to claim 1, characterized in that: The processing module also includes an MCU chip, which is used to execute logic programs, process input signals and output control commands.

6. A combined controller according to claim 1, characterized in that: The power supply module also includes a power module and a relay fixed to the PCB board.

7. A combined controller according to claim 1, characterized in that: The buckle structure includes a buckle (4), the upper cover buckle is fixed to the housing and is an integral piece, and the buckle (4) has a screw mounting hole for embedding on the panel with holes by mounting screw controller.

8. A combined controller according to claim 7, characterized in that: The snap-fit ​​structure includes a fixing component and a mounting component. The fixing component is fixed to the panel, and the mounting component is fixed to both sides of the top cover.

9. A combined controller according to claim 8, characterized in that: The fixing component includes a fixing block (5) and a movable component connected within the fixing block. The mounting component includes a slider (6) with a slot (7) on the slider (6) for fitting the movable component, which is used to accommodate the movable component and lock the mounting component in place.

10. A combined controller according to claim 9, characterized in that: The movable component includes a locking block (8) movably connected to the fixed block, a connecting rod (9) fixed to the locking block (8), a spring fixed to the fixed block (5), and a pull plate fixed to the other side of the connecting rod (9), for locking the slider (6) in the fixed block (5).

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