Anti-interference industrial field bus data acquisition relay device

Abstract

The utility model discloses an anti -interference type industrial fieldbus data acquisition relay device relates to industrial automation control technical field, this device includes shell, main control unit and first, second double link interface of being separately arranged on the shell, shell is equipped with movable baffle, and can slide to three positions, and selectively shield all interfaces, only expose first link interface or expose all interfaces, realize physical foolproof and protection, main control unit parallelly receives and handles two link signals, and through health degree evaluation intelligence selects one as active signal source and forwards, when this link failure, seamless switching to another link, the utility model discloses through double link redundancy, intelligent arbitration and mechanical foolproof structure combination, has improved communication reliability, anti -interference and operating safety significantly.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation control technology, specifically to an anti-interference industrial fieldbus data acquisition relay device. Background Technology

[0002] As the "nerve network" of automation systems, the continuity and reliability of industrial fieldbus communication directly affect production safety and efficiency. Repeaters are key devices for extending bus distances and enhancing network topology flexibility, and are widely deployed in complex industrial environments. However, currently widely used traditional fieldbus repeaters still have several significant shortcomings when dealing with high-reliability scenarios:

[0003] First, in terms of reliability, most relay devices adopt a single-link design, that is, they only have a single signal transmission and reception channel. Once this channel is interrupted due to physical damage to the line, loose connectors, increased electromagnetic interference, or port circuit failure, the entire bus communication will be completely paralyzed, forming a fatal single point of failure. This is unacceptable for continuous production processes or safety-critical applications.

[0004] Secondly, at the operation and maintenance level, the interfaces lack effective physical anti-misconnection management; with numerous field devices and complex cables, maintenance personnel are prone to misconnection when wiring between different links or devices, which may lead to network communication abnormalities or even device logic errors.

[0005] In addition, the industrial environment is harsh, filled with dust and oil; the interfaces of existing relay devices are mostly directly exposed, lacking targeted protection. Utility Model Content

[0006] (a) Technical problems to be solved

[0007] To address the shortcomings of existing technologies, this utility model provides an anti-interference industrial fieldbus data acquisition relay device, which solves the aforementioned problems.

[0008] (II) Technical Solution

[0009] To achieve the above objectives, this utility model is implemented through the following technical solution: an anti-interference industrial fieldbus data acquisition relay device, comprising a housing 1 and a main control unit disposed within the housing 1;

[0010] The side wall of the outer casing 1 is provided with a first input interface A1, a first output interface A2, a second input interface B1, and a second output interface B2;

[0011] The side wall of the outer casing 1 is also provided with a movable baffle 2, which is movably configured to selectively expose or cover the interface;

[0012] The device further includes:

[0013] The first input link module has its input end connected to the first input interface A1 and its output end connected to the main control unit.

[0014] The first output link module has its input end connected to the main control unit and its output end connected to the first output interface A2.

[0015] The second input link module has its input end connected to the second input interface B1 and its output end connected to the main control unit.

[0016] The second output link module has its input end connected to the main control unit and its output end connected to the second output interface B2.

[0017] The main control unit is configured to: receive and process signals from the first input link module and the second input link module in parallel; select one as the active signal source according to a preset health assessment strategy; and control the corresponding output link module to forward the signal; when the link corresponding to the active signal source fails, control the signal source and the output link to switch synchronously to another link.

[0018] By adopting the above technical solution, a complete and independent first and second dual communication link was constructed, realizing physical layer redundancy backup. The intelligent arbitration and synchronous switching mechanism of the main control unit ensures that when the primary link is interrupted due to interference or fault, it can seamlessly switch to the backup link in a very short time, greatly improving the continuity and reliability of industrial fieldbus communication and solving the single point of failure risk of single-link relay devices.

[0019] Preferably, it also includes a status indicator unit connected to the main control unit, the status indicator unit including indicator lights 3 for indicating link status and currently active links.

[0020] By adopting the above technical solution, operators and maintenance personnel can quickly and remotely identify the working status of the device, such as power supply, link normal / fault, and currently active link, through the intuitive indicator light 3. This greatly facilitates the monitoring and troubleshooting of on-site equipment and improves the maintainability of the system.

[0021] Preferably, the movable baffle 2 includes a cover plate 21, on which a first set of through holes 22 corresponding to the first input interface A1 and the first output interface A2, and a second set of through holes 23 corresponding to the second input interface B1 and the second output interface B2 are provided; the movable baffle 2 has at least three working positions:

[0022] In the first position, the first group of through holes 22 and the second group of through holes 23 are both offset from the corresponding interfaces to cover all interfaces;

[0023] The second position is such that the first set of through holes 22 are aligned with the first input interface A1 and the first output interface A2, while the second set of through holes 23 are offset from the second input interface B1 and the second output interface B2.

[0024] In the third position, the first set of through holes 22 are aligned with the first input interface A1 and the first output interface A2, and the second set of through holes 23 are aligned with the second input interface B1 and the second output interface B2.

[0025] By adopting the above technical solution, the movable baffle 2 and its multi-position design provide partitioned physical protection and management for the two independent link interfaces. It not only prevents dust, oil, and other contaminants from entering unused interfaces, but also serves as an effective measure to prevent incorrect connection. When only the first link needs to be operated, the second link interface is automatically covered, effectively preventing misconnection; when both links need to be operated simultaneously, both can be opened. This reduces the probability of wiring errors in the field and improves operational safety.

[0026] Preferably, the movable baffle 2 further includes a movable plate 24 connected to the cover plate 21, and the outer shell 1 is provided with a sliding groove 11 for the movable plate 24 to slide; the movable plate 24 is provided with an elastic positioning component 25, and the outer shell 1 is provided with a plurality of positioning grooves 26 corresponding to each working position of the movable baffle 2, and the retaining ball 252 of the elastic positioning component can selectively engage in the positioning groove 26 to achieve flexible positioning.

[0027] By adopting the above technical solution, the combination of the sliding structure and the elastic positioning component makes the position switching operation of the movable baffle 2 smooth and with a clear sense of segmentation. When the operator moves the baffle, they can clearly perceive whether it has accurately reached the preset working position through the tactile and auditory feedback of the ball 252 falling into different positioning slots 26. Accurate positioning can be achieved without visual confirmation, improving the convenience and reliability of operation.

[0028] Preferably, the elastic positioning component 25 includes a housing 251, the retaining ball 252, and a spring 253, wherein the retaining ball 252 is elastically supported within the housing 251 by the spring 253.

[0029] By adopting the above technical solution, the spring 253 provides a stable elastic force to ensure the firm engagement of the ball 252 with the positioning groove 26; at the same time, the structure is durable and easy to manufacture and assemble.

[0030] Preferably, the movable plate 24 is penetrated by a screw 27, and a knob 28 is connected to the screw 27. The outer casing 1 is provided with threaded holes 29 corresponding to each working position. Rotating the knob 28 can make the screw 27 threadedly connected to the selected threaded hole 29 to lock the movable baffle 2.

[0031] By adopting the above technical solution, a mechanical hard locking mechanism consisting of screw 27 and threaded hole 29 is added to the elastic flexible positioning. When the baffle moves to the required position, it can be absolutely fixed by tightening knob 28, completely eliminating the possibility of the baffle position loosening due to long-term vibration or accidental collision in harsh industrial environments, and providing the highest level of physical protection and locking for the interface.

[0032] Preferably, the main control unit is connected to a fault recording memory for recording link switching events and abnormal information.

[0033] By adopting the above technical solution, any link switching, communication error, or other events, along with their timestamps, are recorded in non-volatile memory. This provides valuable data for post-event analysis of network failure causes, assessment of link reliability, and preventative maintenance, greatly enhancing the system's diagnosability.

[0034] Preferably, the first input link module, the first output link module, the second input link module, and the second output link module all include a signal isolation protection unit.

[0035] By adopting the above technical solution, isolation protection, such as optocouplers and isolation transformers, is set up at the signal input and output ports of each link, achieving complete electrical isolation between the internal main control circuit and the external fieldbus. This effectively blocks ground loop interference, potential difference, and surge impact from the field, protecting the core circuit safety. It is a key measure to improve the anti-interference capability and long-term operational stability of the device in complex industrial electromagnetic environments.

[0036] Preferably, the main control unit is equipped with a dual-link arbitration module, which is used to verify, compare and select the best among the two data frames received in parallel.

[0037] By adopting the above technical solution, intelligent arbitration logic is embedded in the main control unit. This module not only monitors link connectivity but also performs real-time verification (such as CRC), timing, and signal quality analysis on two simultaneously received data streams. Based on the analysis results, it automatically selects the optimal data frame for forwarding or achieves load balancing when both streams are functioning normally. This further improves the accuracy and efficiency of communication at the data link layer, surpassing simple hardware switching.

[0038] Preferably, the device further includes a diagnostic interface unit connected to the main control unit.

[0039] By adopting the above technical solution, maintenance personnel can connect to the host computer through this interface to conveniently read the real-time status of the device, configuration parameters, download historical data from the fault record storage, and even perform firmware upgrades or parameter configurations, thereby realizing refined management and maintenance of the device and reducing long-term operation and maintenance costs.

[0040] (III) Beneficial Effects

[0041] This utility model provides an anti-interference industrial fieldbus data acquisition relay device. It has the following beneficial effects:

[0042] 1. By constructing completely independent and symmetrical first and second dual communication links, and combining them with the intelligent dual-link arbitration module integrated in the main control unit, the device can monitor the communication quality of the two links in parallel. When the primary link fails for any reason, the system can automatically and seamlessly switch the data source and forwarding path to the backup link within milliseconds. This process is completely transparent to the upper-layer application, ensuring uninterrupted bus communication under extreme conditions, and greatly improving the availability and security of the entire control system.

[0043] 2. The unique movable baffle design and its multi-position locking mechanism combine physical protection with operational logic. When only a single link needs to be connected, the movable baffle can forcibly cover another set of interfaces, physically eliminating the possibility of misconnection. When dual-link redundancy is required, all links can be opened. This not only provides dust and contamination protection but also serves as an intuitive "physical programming" interface, guiding operators to connect wires correctly, greatly improving the accuracy and safety of on-site operations. It is especially suitable for industrial sites with high personnel flow or complex operating environments. Attached Figure Description

[0044] Figure 1 This is a schematic diagram of the structure of this utility model;

[0045] Figure 2 This is a structural block diagram of the present invention;

[0046] Figure 3 This is a schematic diagram of the structure of the movable baffle in the first position in this utility model;

[0047] Figure 4 This is a schematic diagram of the structure of the movable baffle in the second position in this utility model;

[0048] Figure 5 This is a schematic diagram of the structure of the movable baffle in the third position in this utility model;

[0049] Figure 6 This is a schematic diagram of the movable plate structure in this utility model;

[0050] Figure 7 This is a schematic diagram of the elastic positioning component structure in this utility model.

[0051] In the figure: outer shell 1, first input interface A1, first output interface A2, second input interface B1, second output interface B2, movable baffle 2, cover plate 21, first set of through holes 22, second set of through holes 23, movable plate 24, slide groove 11, elastic positioning component 25, housing 251, retaining ball 252, spring 253, positioning groove 26, screw 27, knob 28, threaded hole 29, and indicator light 3. Detailed Implementation

[0052] The following is in conjunction with the appendix Figure 1 -Appendix Figure 7 This application will be described in further detail below.

[0053] Please see Figures 1 to 7 This utility model provides an anti-interference industrial fieldbus data acquisition relay device. This device aims to provide highly reliable data relay and redundant link switching functions for industrial fieldbuses (such as PROFIBUS, MODBUS, CAN, etc.), while also possessing excellent anti-interference and physical protection characteristics.

[0054] Example 1:

[0055] like Figure 1 and Figure 2 As shown, the device as a whole includes a housing 1 made of metal or high-strength engineering plastic, and a core electronic system and mechanical protection structure encapsulated inside it. On one side wall of the housing 1, from left to right, a first input interface A1, a first output interface A2, a second input interface B1, and a second output interface B2 are arranged sequentially.

[0056] Interfaces A1 and A2 together form the physical port of the first communication link, and interfaces B1 and B2 together form the physical port of the second communication link. The two links are physically independent. An indicator light 3 is provided on the top or front panel of the housing 1 to visually display the device's operating status. Furthermore, a movable baffle 2 is provided parallel to the front of the interface area on the side wall of the housing 1.

[0057] like Figure 2 As shown, the main control unit (MCU) and related circuit boards are fixed inside the casing 1. Its electronic system mainly includes the following parts:

[0058] Main Control Unit: As the "brain" of the device, the main control unit is implemented using an industrial-grade microcontroller or programmable logic device. Its core functions are implemented by fixed software algorithms or hardware logic, mainly including:

[0059] Dual-link parallel data reception: Data streams from the first and second communication links are received simultaneously through independent hardware channels (such as UART, CAN controller).

[0060] Dual-link arbitration module: This module performs real-time analysis on two parallel data frames, evaluating metrics including but not limited to: CRC check results, signal level amplitude, and timing stability of data frame arrival. Based on preset strategies (such as error rate thresholds and signal quality weighted scoring), this module dynamically selects one link as the active signal source and determines its data as the optimal frame.

[0061] Seamless switching control: When the dual-link arbitration module determines that the health of the currently active link is lower than the preset fault threshold (such as communication timeout, continuous verification errors), the main control unit immediately executes the switching command. The switching process is synchronous: on the one hand, the data source is switched from the faulty link (first communication link) to the healthy link (second communication link); on the other hand, the corresponding signal output channel is controlled to ensure that the data is forwarded to the downstream network through the output port (B2) of the second communication link.

[0062] Signal isolation protection unit: Located between the interface and the main control unit, it uses optocouplers or magnetic isolation chips to achieve electrical isolation of up to several kilovolts. This unit also integrates transient suppression devices such as TVS diodes and gas discharge tubes to resist overvoltage and overcurrent interference that may occur in the field, such as surges and electrostatic discharges, ensuring the safety of the internal core circuitry.

[0063] Status indicator unit: connected to the main control unit, drives indicator light 3. Indicator light 3 is designed as multi-color LED or grouped LED, used to indicate: device power status, first communication link working / fault status, second communication link working / fault status, and which link is currently in active forwarding state.

[0064] Fault Log Storage: This uses non-volatile memory (such as EEPROM or FLASH) and is connected to the main control unit. When events such as link switching or communication error count exceeding the limit occur, the main control unit automatically stores the event type, precise timestamp, and a snapshot of the relevant link's status into this storage, forming an operation log.

[0065] Diagnostic interface unit: This unit can be equipped with a physical interface such as USB, RS-232, or Ethernet to connect to the main control unit. Through this interface, maintenance personnel can use host computer software to read real-time status, query historical fault records, modify configuration parameters, or perform firmware updates.

[0066] Power module: Provides a stable and clean DC power supply for all circuits within the device. It typically supports a wide voltage input (e.g., 12-36V DC) and includes filtering and voltage regulation circuitry to suppress interference from industrial power lines.

[0067] During on-site deployment, the bus cables are first connected according to the network plan (single-link or dual-link redundancy). After the device is powered on, the main control unit starts, and the dual links begin operation. Indicator light 3 displays the current status of each link and the active link. During operation, the main control unit continuously performs dual-link monitoring and arbitration. Once an active link fails, seamless switching is immediately triggered, and the switching event is recorded. During maintenance, a computer can be connected via the diagnostic interface to download fault records for analysis, enabling predictive maintenance.

[0068] This invention combines a highly reliable dual-link redundant electronic system with an innovative partitioned protection mechanical structure, which not only ensures the continuity and anti-interference of communication from an electrical perspective, but also improves the correctness and convenience of field wiring from a physical operation perspective, and provides good environmental protection, making it especially suitable for industrial sites with complex environments and high reliability requirements.

[0069] Example 2:

[0070] like Figure 1 , Figure 3 , Figure 4 , Figure 5 , Figure 6 and Figure 7 As shown, the movable baffle 2 is a key mechanical structure for realizing interface partition management and physical prevention of incorrect insertion.

[0071] The movable baffle 2 mainly consists of a cover plate 21 and a movable plate 24 fixedly connected to it. The cover plate 21 is precisely provided with two sets of through holes: the first set of through holes 22 (two, longer) corresponds to the positions of interfaces A1 and A2 of the first communication link; the second set of through holes 23 (two, shorter) corresponds to the positions of interfaces B1 and B2 of the second communication link.

[0072] The outer casing 1 has a groove 11 machined on it. A movable plate 24 is embedded in the groove 11 and can slide longitudinally along it. To achieve precise sensing and temporary fixing of the sliding position, an elastic positioning component 25 is installed on the movable plate 24. Figure 7 As shown, the component includes a housing 251 fixed within a movable plate 24 and a retaining ball 252 elastically pushed downwards by a spring 253. At the bottom of the slide groove 11, three positioning grooves 26 are equidistantly machined along the sliding direction. When the movable plate 24 slides to a specific position, the retaining ball 252, under the action of the spring 253, engages with the corresponding positioning groove 26, achieving flexible positioning and indicating that the baffle has reached the preset working position.

[0073] To ensure the absolute reliability of the baffle position in a vibrating environment, a mechanical locking mechanism is provided. A screw 27 vertically penetrates the movable plate 24 and is threaded into it, with a knob 28 mounted on the top of the screw 27. At the bottom of the slide groove 11, corresponding to the positions of the three positioning slots 26, threaded holes 29 are machined. After the baffle slides into place and completes flexible positioning, the knob 28 can be tightened, driving the lower end of the screw 27 to screw into the corresponding threaded hole 29, thereby achieving a hard lock and preventing any accidental movement.

[0074] The movable baffle 2 is designed with three clearly defined working positions, such as Figure 3 , 4 As shown in Figure 5:

[0075] First position: Slide the movable baffle 2 to the far right (or initial position). At this time, the first set of through holes 22 and the second set of through holes 23 are completely offset from all the interfaces (A1, A2, B1, B2) behind. The solid part of the cover plate 21 tightly covers all interfaces to prevent dust and oil from entering, which is suitable for equipment storage or transportation.

[0076] In the second position, release knob 28 and slide the movable baffle 2 one position to the left. The retaining ball 252 of the elastic positioning component 25 engages with the second positioning slot 26. At this time, the longer hole of the first set of through holes 22 is aligned with the first input interface A1 and the first output interface A2, allowing the cable connector of the first communication link to be inserted. The second set of through holes 23 remains offset from the interfaces (B1, B2) of the second communication link, and the cover plate 21 continues to cover the interface of the second communication link. This state forces the operator to connect only the first communication link, effectively preventing the second communication link from being mistakenly connected when only one link is needed, thus providing a physical foolproof function. After positioning, knob 28 can be tightened to lock it.

[0077] Third position: Continue sliding the movable baffle 2 to the leftmost position, and the retaining ball 252 engages with the third positioning slot 26. At this time, the first set of through holes 22 remains aligned with the first communication link interface, while the second set of through holes 23 is also aligned with the second input interface B1 and the second output interface B2 of the second communication link. All four interfaces of the two sets of links are exposed, allowing simultaneous wiring of both links for redundant network configuration.

[0078] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An anti-interference industrial fieldbus data acquisition relay device, comprising a housing (1) and a main control unit disposed within the housing (1), characterized in that: The side wall of the outer casing (1) is provided with a first input interface (A1), a first output interface (A2), a second input interface (B1) and a second output interface (B2); The side wall of the outer casing (1) is also provided with a movable baffle (2), which is movably configured to selectively expose or cover the interface; The device further includes: The first input link module has its input end connected to the first input interface (A1) and its output end connected to the main control unit; The first output link module has its input end connected to the main control unit and its output end connected to the first output interface (A2); The second input link module has its input end connected to the second input interface (B1) and its output end connected to the main control unit; The second output link module has its input end connected to the main control unit and its output end connected to the second output interface (B2); The main control unit is configured to: receive and process signals from the first input link module and the second input link module in parallel; select one as the active signal source according to a preset health assessment strategy; and control the corresponding output link module to forward the signal; when the link corresponding to the active signal source fails, control the signal source and the output link to switch synchronously to another link.

2. The anti-interference industrial fieldbus data acquisition relay device according to claim 1, characterized in that: It also includes a status indicator unit connected to the main control unit, the status indicator unit including indicator lights (3) for indicating link status and currently active links.

3. The anti-interference industrial fieldbus data acquisition relay device according to claim 1, characterized in that: The movable baffle (2) includes a cover plate (21), on which a first set of through holes (22) corresponding to the first input interface (A1) and the first output interface (A2) are provided, and a second set of through holes (23) corresponding to the second input interface (B1) and the second output interface (B2) are provided; the movable baffle (2) has at least three working positions: In the first position, the first group of through holes (22) and the second group of through holes (23) are both offset from the corresponding interfaces to cover all interfaces; In the second position, the first set of through holes (22) are aligned with the first input interface (A1) and the first output interface (A2), while the second set of through holes (23) are offset from the second input interface (B1) and the second output interface (B2); In the third position, the first set of through holes (22) are aligned with the first input interface (A1) and the first output interface (A2), and the second set of through holes (23) are aligned with the second input interface (B1) and the second output interface (B2).

4. The anti-interference industrial fieldbus data acquisition relay device according to claim 3, characterized in that: The movable baffle (2) also includes a movable plate (24) connected to the cover plate (21). The outer shell (1) is provided with a sliding groove (11) for the movable plate (24) to slide. The movable plate (24) is provided with an elastic positioning component (25). The outer shell (1) is provided with multiple positioning grooves (26) corresponding to each working position of the movable baffle (2). The ball (252) of the elastic positioning component can selectively engage in the positioning groove (26) to achieve flexible positioning.

5. The anti-interference industrial fieldbus data acquisition relay device according to claim 4, characterized in that: The elastic positioning component (25) includes a housing (251), a ball (252), and a spring (253). The ball (252) is elastically supported in the housing (251) by the spring (253).

6. The anti-interference industrial fieldbus data acquisition relay device according to claim 4, characterized in that: The movable plate (24) is penetrated by a screw (27), and a knob (28) is connected to the screw (27). The outer shell (1) is provided with threaded holes (29) corresponding to each working position. Rotating the knob (28) can make the screw (27) threadedly connected to the selected threaded hole (29) to lock the movable baffle (2).

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