Programmable control box

Abstract

The utility model discloses a programmable control box belongs to control cabinet technical field, including air switch, PLC, alarm module, isolation simulation module, solid state relay module, I / 0 submodule and mode switch, solve the technical problem that the present programmable control box lacks hardware isolation and safe mode switching in the field programming and operation process, easily lead to output misoperation, the utility model discloses effectively avoid debugging or the misoperation of external load in the process of downloading procedure, realize the manual authorization control of operation mode and programming mode, prevent the misoperation of unauthorised personnel, improve the security and manageability of field use, improve the fault tolerance and reliability of system, the utility model discloses on the basis of traditional PLC control box structure, introduce the functional extension of standardization electrical module, and the interface between module is clear, and the versatility is strong, and the installation, maintenance and subsequent function upgrading are convenient.

Description

Technical Field

[0001] This utility model belongs to the field of control cabinet technology, and in particular relates to a programmable control box. Background Technology

[0002] With the development of industrial automation systems, control boxes are widely used in applications such as fan control, equipment linkage, and alarm output. Existing general-purpose control boxes typically use a PLC as the core control unit, and use relays or solid-state relays to realize the input acquisition and output control of switching signals. Their structure is relatively simple, the cost is low, and they can meet basic control requirements.

[0003] However, existing control boxes still have the following shortcomings in practical engineering applications:

[0004] Lack of effective isolation between programming and operation: In existing control boxes, the output of PLC usually directly drives relays or solid-state relays. When debugging, downloading or modifying PLC programs on site, the control output is still in an operational state, which can easily lead to external load malfunctions due to misoperation or program abnormalities, posing a safety hazard.

[0005] Lack of clear mode switching and authorization mechanism: Existing control boxes mostly distinguish between operating and debugging states through software, lacking independent hardware mode switching devices. They cannot physically isolate and authorize the "operating mode" and "programming mode", making it difficult to prevent unauthorized personnel from operating on-site.

[0006] Functional expansion relies on software implementation, resulting in insufficient system robustness. Existing technologies typically implement multiple control and protection functions through PLC software logic. Once the PLC program malfunctions or the controller fails, the relevant protection functions will fail, and the overall anti-interference capability and stability of the system need to be improved. Utility Model Content

[0007] The purpose of this invention is to provide a programmable control box that solves the technical problem that existing programmable control boxes lack hardware isolation and safe mode switching during on-site programming and operation, which can easily lead to output malfunctions.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] A programmable control box includes an air switch, a PLC, an alarm module, an isolation simulation module, a solid-state relay module, an I / O sub-module, and a mode switching switch;

[0010] The input terminal of the circuit breaker is connected to the mains power, and the output terminal supplies power to the PLC; the PLC outputs a 24V power supply, which includes a DC24V positive terminal and a DC0V negative terminal.

[0011] The alarm module, isolation simulation module, I / O sub-module, and mode switching switch are all connected to the PLC;

[0012] The mode switching switch is also connected to the isolation simulation module; the solid-state relay module is also connected to the isolation simulation module.

[0013] The RUN and PROG terminals of the SPDT key knob are mutually exclusive.

[0014] Preferably, the isolation simulation module includes isolation switches DPDT1 and DPDT2; the solid-state relay module is a solid-state relay group (SSR); and the mode switching switch is a key knob (SPDT).

[0015] The COM terminal of the key knob SPDT is connected to the positive terminal of DC24V, the RUN terminal is connected to the DI7 terminal of the PLC, and the PROG terminal is connected to the coil A terminal of disconnect switch DPDT1 and the coil A terminal of disconnect switch DPDT2 respectively; the coil B terminals of disconnect switches DPDT1 and DPDT2 are both connected to the negative terminal of DC0V.

[0016] The NO1 terminal of the disconnecting switch DPDT1 is connected to the DO1 terminal of the PLC, the NC1 terminal is connected to the DC24V positive terminal, and the COM1 terminal is connected to the CH1+ terminal of the solid-state relay group SSR; the CH1- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal.

[0017] The NO2 terminal of the disconnecting switch DPDT1 is connected to the DO2 terminal of the PLC, the NC2 terminal is connected to the DC24V positive terminal, and the COM2 terminal is connected to the CH2+ terminal of the solid-state relay group SSR; the CH2- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal.

[0018] The NO1 terminal of the disconnecting switch DPDT2 is connected to the DO3 terminal of the PLC, the NC1 terminal is connected to the DC24V positive terminal, and the COM1 terminal is connected to the CH3+ terminal of the solid-state relay group SSR; the CH3- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal.

[0019] The NO2 terminal of the disconnecting switch DPDT2 is connected to the DO4 terminal of the PLC, the NC2 terminal is connected to the DC24V positive terminal, and the COM2 terminal is connected to the CH4+ terminal of the solid-state relay group SSR; the CH4- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal.

[0020] The CH1A and CH1B terminals of the solid-state relay (SSR) are a pair of output terminals, the CH2A and CH2B terminals are a pair of output terminals, the CH3A and CH3B terminals are a pair of output terminals, and the CH4A and CH4B terminals are a pair of output terminals.

[0021] Preferably, the air switch is model iC65N; the PLC is model S7-1200CPU1214CDC / DC / DC; the alarm module is model AL809U; the disconnect switches DPDT1 and DPDT2 are both model OmronG2R-2-DC24; the solid-state relay module is model SSR-4DA; the I / O submodule is model PRElectronics3185A1; and the mode switching switch is model HarmonyXB4-BG21.

[0022] This utility model discloses a programmable control box that solves the technical problem of existing programmable control boxes lacking hardware isolation and safe mode switching during on-site programming and operation, which easily leads to output malfunctions. This utility model achieves physical isolation between the PLC and the solid-state relay output circuit in programming mode by setting a mode switching switch and an isolation simulation module, effectively preventing external load malfunctions during debugging or program downloading. A key knob is used as the mode switching switch to enable manual authorized control between the operating mode and the programming mode, preventing unauthorized personnel from misoperating and improving on-site safety and manageability. Through the design of the normally closed contact of the isolation switch and the power supply, the solid-state relay module automatically enters a preset safe output state when the isolation module does not operate or the control is abnormal, improving the system's fault tolerance and reliability. Based on the traditional PLC control box structure, this utility model introduces standardized electrical modules for functional expansion. The interfaces between modules are clear and highly versatile, facilitating installation, maintenance, and subsequent functional upgrades. Attached Figure Description

[0023] Figure 1 This is a hardware architecture diagram of this utility model;

[0024] Figure 2 This is a wiring diagram between the air switch, isolation simulation module, and solid-state relay module of this utility model. Detailed Implementation

[0025] Depend on Figures 1-2 The programmable control box shown includes an air switch, a PLC, an alarm module, an isolation simulation module, a solid-state relay module, an I / O sub-module, and a mode switching switch;

[0026] The input terminal of the circuit breaker is connected to the mains power, and the output terminal supplies power to the PLC; the PLC outputs a 24V power supply, which includes a DC24V positive terminal and a DC0V negative terminal.

[0027] The alarm module, isolation simulation module, I / O sub-module, and mode switching switch are all connected to the PLC;

[0028] The mode switching switch is also connected to the isolation simulation module; the solid-state relay module is also connected to the isolation simulation module.

[0029] The RUN and PROG terminals of the SPDT key knob are mutually exclusive.

[0030] The isolation simulation module includes isolation switches DPDT1 and DPDT2; the solid-state relay module is a solid-state relay group (SSR); the mode switching switch is a key knob (SPDT).

[0031] The COM terminal of the key knob SPDT is connected to the positive terminal of DC24V, the RUN terminal is connected to the DI7 terminal of the PLC, and the PROG terminal is connected to the coil A terminal of disconnect switch DPDT1 and the coil A terminal of disconnect switch DPDT2 respectively; the coil B terminals of disconnect switches DPDT1 and DPDT2 are both connected to the negative terminal of DC0V.

[0032] The NO1 terminal of the disconnecting switch DPDT1 is connected to the DO1 terminal of the PLC, the NC1 terminal is connected to the DC24V positive terminal, and the COM1 terminal is connected to the CH1+ terminal of the solid-state relay group SSR; the CH1- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal.

[0033] The NO2 terminal of the disconnecting switch DPDT1 is connected to the DO2 terminal of the PLC, the NC2 terminal is connected to the DC24V positive terminal, and the COM2 terminal is connected to the CH2+ terminal of the solid-state relay group SSR; the CH2- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal.

[0034] The NO1 terminal of the disconnecting switch DPDT2 is connected to the DO3 terminal of the PLC, the NC1 terminal is connected to the DC24V positive terminal, and the COM1 terminal is connected to the CH3+ terminal of the solid-state relay group SSR; the CH3- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal.

[0035] The NO2 terminal of the disconnecting switch DPDT2 is connected to the DO4 terminal of the PLC, the NC2 terminal is connected to the DC24V positive terminal, and the COM2 terminal is connected to the CH4+ terminal of the solid-state relay group SSR; the CH4- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal.

[0036] The CH1A and CH1B terminals of the solid-state relay (SSR) are a pair of output terminals, the CH2A and CH2B terminals are a pair of output terminals, the CH3A and CH3B terminals are a pair of output terminals, and the CH4A and CH4B terminals are a pair of output terminals.

[0037] This embodiment mainly uses a PLC control core, an isolation simulation module, a solid-state relay module, an alarm module, and a mode switching switch to form a safe and programmable control system.

[0038] The control box is connected to AC power via an air switch (Schneider iC65N series) to provide AC power to the PLC, alarm module, isolation simulation module, and solid-state relay module. After the PLC is powered on, it initializes its internal logic (which is programmed by the user), and the DI / DO ports are ready. At the same time, it provides DC power (DC24V positive and DC0V negative) to the modules through its built-in 24VDC output.

[0039] The control box is equipped with a key-knob SPDT mode switch, which has two modes: RUN (run) and PROG (program).

[0040] When the key is in the RUN position, the RUN terminal activates the PLC's DI7 input, and the PLC determines that it is in running mode. The isolation simulation module (composed of two DPDT relays) is not powered on, and the output circuit of the solid-state relay module maintains a preset safety state based on normally closed contacts.

[0041] When the key is turned to the PROG position, the PROG terminal supplies power to the DPDT relay coil, causing the isolation simulation module to switch contacts and physically connect the PLC's output to the solid-state relay module, thus enabling programming mode. At this time, the PLC can operate the DO output without affecting the operation of the field load, thereby achieving hardware isolation between the programming and operational circuits.

[0042] The PLC's DI port can acquire status signals from external sensors, digital inputs, or alarm modules, including field buttons, fan status, and flue gas alarms. Input isolation and signal filtering are provided through the I / O submodule (PRElectronics3185A1) to ensure stable and reliable signals acquired by the PLC, preventing interference or transient pulses from causing malfunctions in the control logic.

[0043] The PLC's DO output port is connected to a solid-state relay module (Fotek SSR-4DA) via an isolation simulation module. The isolation simulation module can switch contacts based on the state of the mode switch.

[0044] In RUN mode, the PLC output signal can directly control the solid-state relay module to drive the operation of external load equipment (such as fan start-up and alarm light illumination).

[0045] In PROG mode, the PLC output signal is still operable, but it is isolated from the load circuit by the isolation simulation module, so it does not affect the field equipment and ensures debugging safety.

[0046] The solid-state relay module amplifies the PLC's switching signals and drives them to the load, supporting high-current load control (8A per channel). The output terminals (CH1A / CH1B...CH4A / CH4B) are connected to field devices to ensure rapid device response and eliminate mechanical contact wear issues.

[0047] The control box also features LED indicators as an alarm module. When the PLC detects an abnormal state through the DO output or I / O submodule signal, the corresponding LED will light up. Driven by a DC24V power supply and a current-limiting resistor, the LEDs visually display the system's operating status, fault alarms, and mode status, allowing on-site operators to quickly assess the system's working condition.

[0048] The normally closed contacts of the isolation simulation module keep the solid-state relay in a safe state when the system is not powered on or the relay is not activated. The I / O submodule provides electrical isolation and filtering to ensure the anti-interference capability of the input signal. The key switch mode control provides manual authorization to prevent unauthorized personnel from accidentally operating the PLC and ensure the safety of field equipment.

[0049] The air switch is model iC65N; the PLC is model S7-1200CPU1214CDC / DC / DC; the alarm module is model AL809U; the disconnect switches DPDT1 and DPDT2 are both model OmronG2R-2-DC24; the solid-state relay module is model SSR-4DA; the I / O submodule is model PRElectronics3185A1, and in this embodiment, multiple I / O submodules can be set according to field requirements; the mode switching switch is model HarmonyXB4-BG21.

[0050] This utility model discloses a programmable control box that solves the technical problem of existing programmable control boxes lacking hardware isolation and safe mode switching during on-site programming and operation, which easily leads to output malfunctions. This utility model achieves physical isolation between the PLC and the solid-state relay output circuit in programming mode by setting a mode switching switch and an isolation simulation module, effectively preventing external load malfunctions during debugging or program downloading. A key knob is used as the mode switching switch to enable manual authorized control between the operating mode and the programming mode, preventing unauthorized personnel from misoperating and improving on-site safety and manageability. Through the design of the normally closed contact of the isolation switch and the power supply, the solid-state relay module automatically enters a preset safe output state when the isolation module does not operate or the control is abnormal, improving the system's fault tolerance and reliability. Based on the traditional PLC control box structure, this utility model introduces standardized electrical modules for functional expansion. The interfaces between modules are clear and highly versatile, facilitating installation, maintenance, and subsequent functional upgrades.

Claims

1. A programmable control box, characterized in that: Includes air switches, PLC, alarm modules, isolation simulation modules, solid-state relay modules, I / O sub-modules, and mode switching switches; The input terminal of the circuit breaker is connected to the mains power, and the output terminal supplies power to the PLC; the PLC outputs a 24V power supply, which includes a DC24V positive terminal and a DC0V negative terminal. The alarm module, isolation simulation module, I / O sub-module, and mode switching switch are all connected to the PLC; The mode switching switch is also connected to the isolation simulation module; the solid-state relay module is also connected to the isolation simulation module. The RUN and PROG terminals of the SPDT key knob are mutually exclusive.

2. The programmable control box as described in claim 1, characterized in that: The isolation simulation module includes isolation switches DPDT1 and DPDT2; the solid-state relay module is a solid-state relay group (SSR); the mode switching switch is a key knob (SPDT). The COM terminal of the key knob SPDT is connected to the positive terminal of DC24V, the RUN terminal is connected to the DI7 terminal of the PLC, and the PROG terminal is connected to the coil A terminal of disconnect switch DPDT1 and the coil A terminal of disconnect switch DPDT2 respectively; the coil B terminals of disconnect switches DPDT1 and DPDT2 are both connected to the negative terminal of DC0V. The NO1 terminal of the disconnecting switch DPDT1 is connected to the DO1 terminal of the PLC, the NC1 terminal is connected to the DC24V positive terminal, and the COM1 terminal is connected to the CH1+ terminal of the solid-state relay group SSR; the CH1- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal. The NO2 terminal of the disconnecting switch DPDT1 is connected to the DO2 terminal of the PLC, the NC2 terminal is connected to the DC24V positive terminal, and the COM2 terminal is connected to the CH2+ terminal of the solid-state relay group SSR; the CH2- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal. The NO1 terminal of the disconnecting switch DPDT2 is connected to the DO3 terminal of the PLC, the NC1 terminal is connected to the DC24V positive terminal, and the COM1 terminal is connected to the CH3+ terminal of the solid-state relay group SSR; the CH3- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal. The NO2 terminal of the disconnecting switch DPDT2 is connected to the DO4 terminal of the PLC, the NC2 terminal is connected to the DC24V positive terminal, and the COM2 terminal is connected to the CH4+ terminal of the solid-state relay group SSR; the CH4- terminal of the solid-state relay group SSR is connected to the DC0V negative terminal. The CH1A and CH1B terminals of the solid-state relay (SSR) are a pair of output terminals, the CH2A and CH2B terminals are a pair of output terminals, the CH3A and CH3B terminals are a pair of output terminals, and the CH4A and CH4B terminals are a pair of output terminals.

3. The programmable control box as described in claim 2, characterized in that: The air switch is model iC65N; the PLC is model S7-1200CPU1214CDC / DC / DC; the alarm module is model AL809U; the disconnect switches DPDT1 and DPDT2 are both model OmronG2R-2-DC24; the solid-state relay module is model SSR-4DA; the I / O submodule is model PRElectronics3185A1; and the mode switching switch is model HarmonyXB4-BG21.

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