CN110048472B - Standby power supply operation method of controller - Google Patents

Abstract

The invention discloses a standby power supply operation method of a controller. The standby power supply operation method comprises the following steps: firstly, starting power supply through an input power supply; then, executing a charging program, charging the energy storage circuit to a voltage threshold value in a first charging mode, and switching to a second charging mode when the voltage threshold value is reached, so as to continuously charge the energy storage circuit to a full-charge voltage value, wherein the first charging mode starts from a maximum current value and gradually reduces the current value, and the second charging mode is a fixed current value and is smaller than the maximum current value; then, the execution of the charging program is suspended; and then, monitoring the power supply state of the input power supply so as to release the stored electric energy to the controller through the energy storage circuit when the power supply of the input power supply is interrupted. The invention can effectively charge to ensure that the energy storage circuit is fully charged, and timely compensates the power supply when the power supply is interrupted, so as to avoid setting or data loss.

Description

Controller backup power operation method

Technical field

The invention belongs to the technical field of power supply systems for controllers, and relates to a backup power supply operating method for a controller.

Background technique

Controllers are used to control various operations of automation or mechanical equipment, such as processing, measurement, and transportation. The operation process usually includes various strokes, such as rotation, movement, and grabbing, etc. The controller is arranged through programs or instructions. Complete various itineraries and operations.

The controller usually requires electric energy to perform various strokes and operations. When the electric energy is continuously and stably supplied, the controller can usually perform various strokes and operations normally. However, if during the execution process, the controller loses power due to factors such as sudden power interruption or sudden drop, it will often cause obvious errors in subsequent strokes or operations. For example, when the controller controls the mechanical equipment to perform a rotational motion, the electric energy is suddenly interrupted during the rotational stroke, causing the controller to be temporarily disabled. After completing the rotational stroke, there is usually a significant deviation. The offset phenomenon is generally caused by the failure of the controller to effectively store the current execution status or data due to power interruption time.

Therefore, the controller usually requires a backup power supply system that is sufficient to provide the same voltage value as the input power supply voltage to compensate for sudden interruptions in power. Currently, the backup power supply system is usually through a DC/DC converter (DC/DC converter) or linear voltage regulator. However, there is a voltage drop in the DC/DC converter or linear regulator, so this charging method usually cannot effectively charge the energy storage element to the same voltage as the input power supply. level, and the charging current will extend the power-on time as the voltage value decreases.

In addition, because the backup power supply will compensate during shutdown or power interruption, the discharge time of the backup power supply will also extend the shutdown time of the controller or system, affecting the waiting time for shutdown or restart.

Contents of the invention

The purpose of the present invention is to efficiently charge the backup power supply to ensure that the backup power supply can be fully charged, and to provide the backup power supply in time when the power supply is interrupted to avoid data or setting loss, not to mention prolonging the shutdown or restart time. .

In order to achieve the above object, the backup power operation method of the controller of the present invention includes: first starting to supply power through the input power; then, executing the charging procedure to charge the energy storage circuit to the voltage threshold value in the first charging mode, and after reaching When the voltage reaches the threshold value, switch to the second charging mode to continue charging the energy storage circuit to the full voltage value. The first charging mode starts from the maximum current value and gradually reduces the current value. The second charging mode is a fixed current. value, and is less than the maximum current value; then, the charging process is suspended; then, the input power supply status is monitored, so that when the input power supply is interrupted, the stored electric energy is released to the controller through the energy storage circuit.

In this way, the backup power operation method of the controller of the present invention can efficiently charge the energy storage circuit through the first and second charging modes in the charging process, and can ensure that the energy storage circuit is fully charged. Furthermore, by monitoring the input power status, timely compensation for interrupted input power is achieved to avoid loss of settings or data.

Description of the drawings

Figure 1 is a flow chart of a backup power operation method of a controller shown in an embodiment of the present invention.

Figure 2 is a flow chart that continues Figure 1 with additional options.

Figure 3 is a flow chart that continues Figure 2 with additional options.

Figure 4 is a block diagram of the backup power operating device of the controller shown in the embodiment of the present invention.

FIG. 5 is a circuit diagram of the backup power operating device of the controller shown in the embodiment of the present invention.

FIG. 6 is an operation sequence diagram of the backup power operating device in FIG. 5 .

【Symbol Description】

10-Process; 11～19, 191～196-Steps;

30-Backup power supply device 31-Judgment circuit;

33-Current management circuit 331-First charging module;

333-second charging module; 335-switching module;

35-Energy storage circuit; 37-Switching circuit;

371-Output terminal; 39-Self-cutting circuit;

391-Relay; 393-Normally open contact;

395-common contact; 50-input power supply;

60-controller; Q1-first transistor;

Q2-the second transistor; Q3-the third transistor;

Q4-the fourth transistor; Q5-the fifth transistor;

R1-the first electrical group; R2-the second resistor;

R3-the third resistor; R4-the fourth resistor;

R5-fifth resistor; R6-sixth resistor;

R7-seventh resistor; R8-eighth resistor;

R9-ninth resistor; D1-diode;

OPA1-the first operational amplifier; OPA2-the second operational amplifier;

V _in - input voltage; Vsc - energy storage voltage;

V ₂₃ , V ₈₉ - divided voltage.

Detailed ways

In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be further described in detail below with reference to specific embodiments and the accompanying drawings.

The controller of the present invention is applied to mechanical equipment to control various operations of the mechanical equipment. The controller includes a variety of control modules, and the control modules are used to control various operations of the mechanical equipment.

As shown in Figure 1, this figure is a flow chart of an operating method according to an embodiment of the present invention. The operating method of the backup power supply device of the present invention illustrates four steps, but this is not a limitation of the present invention. In other embodiments, the order of the steps may be changed, or there may be more or fewer steps.

The process 10 of the operating method of the backup power supply device of the present invention starts with power supply 11 through the input power supply. The input power supply can be direct current or alternating current. In this embodiment, the input power supply is a DC voltage of 24 volts (V). In other embodiments, it can be other voltage values. This step can represent just starting up, power interruption and restoration, or other states. Input power supply refers to power supply to the controller and power supply device.

Then, step 13 is to charge the energy storage circuit to the voltage threshold in the first charging mode. The first charging mode starts with approximately the maximum current value and gradually reduces the charging current value. Generally speaking, when the power is first turned on, the current drawn by the controller or system is the smallest. Therefore, you can take advantage of this time to charge the energy storage circuit with approximately the maximum current to shorten the charging time.

Following step 13, step 15 switches to the second charging mode when the voltage threshold value is reached to continue charging the energy storage circuit to a full voltage value. The second charging mode is to charge with a fixed current value, and the fixed current value is less than the maximum current value. Charging with a fixed current ensures that the energy storage circuit is fully charged. The full voltage value is charged to a voltage value that is approximately equal to the input voltage. Approximately equal can be more than, equal to, or slightly less than. Among them, step 13 and step 15 can be integrated into one step, which is to execute the charging process. In other embodiments, the order of these two steps can also be exchanged.

After that, step 17 is executed to suspend the charging process, that is, steps 13 and 15 are suspended. Step 17 indicates that the energy storage circuit has reached the full voltage value and stops charging the energy storage circuit.

After that, step 19 is to monitor the input power supply status to release the stored power to the controller through the energy storage circuit when the input power supply is interrupted, so that the controller can temporarily operate normally (shut down) to complete data storage and avoid data loss. Generally speaking, the input power supply is continuous, and interruption will only occur when shutdown, power outage, or battery falls off. Therefore, interruption refers to the discontinuity of power due to the aforementioned situation or other situations, but interruption also occurs. It may be that it suddenly disappeared and then returned to normal power supply status.

In this embodiment, the energy storage circuit includes a supercapacitor. In addition to having good energy storage capabilities, the supercapacitor can also quickly release stored electrical energy to promptly compensate for temporarily interrupted power and maintain normal operation of the controller or store data. In other embodiments, the energy storage circuit may also use other storage elements or circuits with similar supercapacitive capabilities.

Because this embodiment first performs charging through the first charging mode with a larger current value, and then continues charging through the second charging mode with a constant current value, the energy storage circuit can be charged faster than in traditional technology.

Continuing the description of Figure 1, additional steps of the present invention are shown in Figure 2, which is a flow chart of the second embodiment of the operating method of the present invention. The second embodiment includes optionally changing step 19 into three steps to complete the function of avoiding data loss. Step 191 is to determine whether the power supply is output normally. This determination is based on the power supply status of the input power supply. If so, step 193 is executed, and the energy storage circuit does not release the stored electric energy. If not, step 195 is executed, and the energy storage circuit releases the stored electric energy to the controller so that the controller has enough power to store data.

Continuing the description of Figure 1, additional steps of the present invention are shown in Figure 3. Figure 3 is a flow chart of the third embodiment of the operating method of the present invention. The third embodiment includes optionally adding two additional steps to step 19 to complete the normal shutdown function. Step 194 is to stop the input power supply, and continue to step 195 to allow the energy storage circuit to release the stored electric energy to the controller within the discharge condition. Then, step 196 is to stop the energy storage circuit to provide power to the controller when the discharge condition is met. to shut down the controller. The discharge condition is related to the time for releasing the electrical energy. In this embodiment, the discharge condition is that the time for releasing the stored electrical energy is less than the total time for releasing the stored electrical energy of the energy storage circuit. In this way, the shutdown or restart time will not be affected by the discharge of the energy storage circuit, and data can be stored and shut down efficiently.

The backup power operation method of the present invention is applied to a controller or system to ensure that when the controller or system is shut down or a power interruption occurs, the controller or system has sufficient power and time to store various settings, codes or Signal. In other embodiments, the backup power operating method can be applied to control modules of multiple controllers or controllers corresponding to multiple backup power supply devices. Therefore, the number and application of the backup power supply devices are not limited to those described in this embodiment. limit.

The steps of executing the charging program, suspending the charging program, and monitoring the input power supply status described in steps 13 to 19 are performed by the backup power supply device. As shown in FIGS. 4 and 5 , the backup power supply device 30 includes a judgment circuit 31 , a current management circuit 33 , an energy storage circuit 35 , a switch circuit 37 and a self-cut circuit 39 . The judgment circuit 31 is connected to the input power supply 50 , the current management circuit 33 and the switch circuit 37 . The current management circuit 33 is connected to the energy storage circuit 35 . The energy storage circuit 35 is connected to the self-cutting circuit 39 . The self-cut circuit 39 is connected to the switch circuit 37 . The switch circuit 37 has an output terminal 371, and the output terminal 371 is connected to the controller 60 or the system.

The current management circuit 33 is used to control the size of the charging current, that is, to select the first charging mode and the second charging mode, which correspond to step 13 (executing the charging process) and step 17 (pausing the charging process) in FIG. 1 .

As shown in FIG. 5 , the current management circuit 33 includes a first charging module 331 , a second charging module 333 and a switching module 335 . The first charging module 331 includes a first transistor Q1 and a first resistor R1. The second charging module 333 includes a constant current circuit to fix the charging current value. The constant current circuit may be an integrated circuit or a circuit composed of active and passive components. The switching module 335 is connected to the input power supply 50, the first charging module 331, the second charging module 333 and the energy storage circuit 35, and includes a second transistor Q2, a third transistor Q3, a second resistor R2, a third resistor R3 and a fourth resistor. R4, the first operational amplifier OPA1.

Among them, the energy storage circuit 35 is a circuit composed of multiple capacitors and multiple resistors. In other embodiments, the number of capacitors and resistors can be changed arbitrarily. Therefore, the number of capacitors of the energy storage circuit 35 is not the same as in this embodiment. The description is limited.

The gate of the first transistor Q1 is connected to the output of the judgment circuit 31 . The source of the first transistor Q1, the second resistor R2, and the input end of the constant current circuit of the second charging module 333 are connected to the input power supply 50 (refer to the symbol Vin). The drain of the first transistor Q1 is connected to the first resistor R1. The other end of the first resistor R1 is connected to the source of the third transistor Q3. The second resistor R2 and the third resistor R3 are connected in series. The positive input terminal of the first operational amplifier OPA1 is connected to the voltage dividing contact of the second resistor R2 and the third resistor R3. The other end of the third resistor R3 is connected to ground. The inverting input terminal of the first operational amplifier OPA1 is connected to the energy storage circuit 35 (reference symbol Vsc). The output terminal of the first operational amplifier OPA1 is connected to the gate of the second transistor Q2, the gate of the third transistor Q3 and the contact point of the fourth resistor R4. The other end of the fourth resistor R4 is connected to the energy storage circuit 35 (refer to symbol Vsc). . The output of the constant current circuit is connected to the source of the second transistor Q2. The drain of the second transistor Q2 and the drain of the third transistor Q3 are connected to the energy storage circuit 35 . Among them, the first transistor Q1 is a PMOS, the second transistor Q2 is a PMOS, and the third transistor Q3 is an NMOS.

As shown in FIGS. 5 and 6 , FIG. 6 is an operation sequence diagram of the backup power supply device. When the power is turned on, referring to area A of Figure 6, the energy storage voltage Vsc of the energy storage circuit 35 is lower than the set voltage threshold, the output of the first operational amplifier OPA1 is high level, the third transistor Q3 is turned on, and the second transistor Q2 is turned off, and the charging current charges the energy storage circuit 35 through the first transistor Q1, the first resistor R1 and the third transistor Q3, that is, charging is performed in the first charging mode. In other embodiments, first transistor Q1 may be omitted.

Among them, the voltage threshold value is related to the divided voltage V ₂₃ of the second resistor R2 and the third resistor R3 and the energy storage voltage Vsc of the energy storage circuit 35; when the divided voltage V ₂₃ is lower than the energy storage voltage Vsc, the first operation The amplifier OPA1 outputs a high level; when the divided voltage V ₂₃ is higher than the energy storage voltage Vsc, the first operational amplifier OPA1 outputs a low level.

Next, referring to area B of FIG. 6 , when the energy storage voltage Vsc of the energy storage circuit 35 is higher than the set voltage threshold, the output of the first operational amplifier OPA1 is low level, the second transistor Q2 is turned on, and the third transistor Q3 is turned off, and the charging current of the energy storage circuit 35 is provided by the constant current circuit of the second charging module 333, and the energy storage circuit 35 is charged through the second transistor Q2, that is, charging is performed in the second charging mode to charge the energy storage circuit. 35 is full. in this way. In the present invention, the switching module 335 changes the path of the charging current according to the output condition of the first operational amplifier OPA1 to perform charging efficiently.

Please continue to refer to Figures 5 and 6. The judgment circuit 31, the switch circuit 37 and the self-cut circuit 39 monitor the input voltage V _{in of} the input power supply 50 (step 19). The judgment circuit 31 is used to monitor the input of the input power supply 50. The voltage V _in power supply status is output normally to generate monitoring results (step 191). The monitoring results include normal power supply (step 193) or interrupted power supply (steps 194-196). The switch circuit 37 controls whether the energy storage circuit 35 releases the stored electric energy based on the monitoring result of the judgment circuit 31. When the monitoring result belongs to normal power supply, the switch circuit 37 controls the energy storage circuit 35 not to release the stored electric energy (step 193); the monitoring result belongs to interruption. When power is supplied, the switch circuit 37 controls the energy storage circuit 35 to release the stored electric energy to the output terminal 371 to the controller (step 195). When the monitoring result of the switch circuit 37 is that the power supply is interrupted (steps 194-196), the self-cut circuit 39 first allows the energy storage circuit 35 to release the stored electric energy to the controller within the discharge condition (step 198), and when the discharge condition is interrupted, the self-cut circuit 39 When satisfied (step 199), the stop energy storage circuit 35 releases the stored electric energy to the controller so that the controller is shut down.

The judgment circuit 31 includes a fifth resistor R5, a sixth resistor R6, a seventh resistor R7 and a second operational amplifier OPA2. The input power supply 50 is connected to the fifth resistor R5, the inverting input terminal of the second operational amplifier OPA2 and its power terminal. The positive input end of the second operational amplifier OPA2 is connected to the voltage dividing contact of the fifth resistor R5 and the sixth resistor R6 connected in series, and the other end of the sixth resistor R6 is connected to ground. The output terminal of the second operational amplifier OPA2 is connected to the gate of the first transistor Q1 of the switching module 335, the seventh electrical group R7 and the switching circuit 37 (symbol Vc in Figure 5). The other end of the seventh resistor R7 is connected to the energy storage circuit 35 (symbol Vsc in Figure 5).

The switch circuit 37 includes a fourth transistor Q4 and a fifth transistor Q5. The gate of the fourth transistor Q4 is connected to the output terminal (refer to symbol Vc) of the second operational amplifier OPA2, its source is connected to the input power supply 50, and its drain is connected to the output terminal 371, that is, connected to the controller or system. The gate of the fifth transistor Q5 is connected to the input power supply 50 and the self-cutting circuit 39, the source is connected to the self-cutting circuit 39, and the drain is connected to the output terminal 371, which is also connected to the controller or system. The fourth transistor Q4 is PMOS, and the fifth transistor Q5 is PMOS.

The self-cutting circuit 39 includes a relay 391, an eighth resistor R8, a ninth resistor R9 and a diode D1. The normally open contact 393 of the relay 391 is connected to the energy storage circuit 35, the common contact 395 of the relay 391 is connected to the source of the fifth transistor Q5, and the relay 391 is connected to the eighth resistor R8, the ninth resistor R9 and the cathode of the diode D1. The other end of the eighth resistor R8 is connected to ground, the other end of the ninth resistor R9 is connected to the energy storage circuit 35, and the anode of the diode D1 is connected to the input power supply V _inc . The relay 391 is based on the voltage division between the eighth resistor R8 and the ninth resistor R9. Voltage V ₈₉ is used for control.

When the input power supply 50 supplies power normally, referring to area C in Figure 6, the second operational amplifier OPA2 outputs a low level, the first transistor 01 and the fourth transistor Q4 are turned on, and the controller or system voltage is provided by the input power supply 50. At this time , the fifth transistor turns off Q5, and the energy storage circuit 35 does not release the stored electric energy.

In addition, during normal power supply, the diode D1 is turned on, and the divided voltage V ₈₉ is also higher than the cut-off voltage value of the relay 391, so that the common contact 395 of the relay 391 is connected to its normally open point 393, indicating that the energy storage circuit 35 is connected to the third through the relay 391. Five transistors Q5 are connected. Among them, the cut-off voltage value of the relay 391 is determined according to its specifications and is well known to those skilled in the art, so it will not be described in detail here. Although the energy storage circuit 35 has been able to release the stored electric energy to the relay 391, the fifth transistor Q5 has not yet been turned on, so the released stored electric energy will not be supplied to the output terminal 371.

When the input power supply 50 is turned off, referring to area D in Figure 6, the diode D1 is cut off, but the divided voltage V ₈₉ is still higher than the cut-off voltage value of the relay 391, so the energy storage circuit 35 can pass the conduction between the relay 391 and the fifth transistor Q5. The path releases the stored electric energy to the output terminal 371, that is, supplies power to the controller or system.

When the energy storage circuit 35 supplies power to the controller or system, causing the voltage V _sc to drop until the divided voltage V ₈₉ is lower than the cut-off voltage value of the relay 391, the common contact 395 of the relay 391 is disconnected from its normally open contact 393, and is disconnected from the normally open contact 393. The energy storage circuit 35 forms an interruption path, and the controller or system will automatically shut down. Therefore, the discharge condition of this embodiment is that the cut-off voltage value is lower than the divided voltage V ₈₉ , and the path for supplying stored electric energy to the switch circuit 37 is cut off. In other embodiments, the discharge condition can also be achieved through timing or other methods, and is not limited to the cut-off voltage value of the relay 371 .

In this way, the backup power operation method of the controller of the present invention can not only efficiently charge the energy storage circuit, but also effectively ensure that various settings or data are stored before shutting down, and the time when the energy storage circuit releases electric energy is also shortened. The shutdown time will not be extended.

The specific embodiments described above further describe the purpose, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above are only specific embodiments of the present invention and are not intended to limit the present invention. , any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included in the protection scope of the present invention.

Claims (7)

1. A backup power operation method for a controller, including: Start supplying power through an input power source; Execute a charging process to charge an energy storage circuit to a voltage threshold in a first charging mode, and switch to a second charging mode when reaching the voltage threshold to continue charging the energy storage circuit to A full voltage value, the first charging mode starts from the maximum current value and gradually reduces the current value, the second charging mode is a fixed current value and is less than the maximum current value; suspend the charging process; and Monitor the power supply status of the input power supply to release the stored electric energy to the controller through the energy storage circuit when the input power supply is interrupted, wherein the execution and suspension steps are performed by a backup power supply device, and the backup power supply device It includes: a current management circuit, including a first charging module, a second charging module, and a switching module. The first charging module is connected to the input power supply, the second charging module is connected to the input power supply, and the switching module is connected to the input power supply. Input power, the first charging module, the second charging module and the energy storage circuit. The first charging module executes the first charging mode, the second charging module executes the second charging mode, and the switching module switches the third charging mode. A charging mode and the second charging mode, wherein the first charging module includes a first transistor and a first resistor; the second charging module includes a certain current circuit; the switching module includes a second transistor and a third transistor , a second resistor, a third resistor, a fourth resistor, a first operational amplifier, the first transistor, the second resistor and the constant current circuit are connected to the input power supply, and the first resistor is connected to the third transistor. The source, the constant current circuit is connected to the source of the second transistor, the second resistor and the third resistor are connected in series, the fourth resistor is connected to the energy storage circuit, and the inverting input end of the first operational amplifier Connect the energy storage circuit, the positive input end of the first operational amplifier is connected to a series of connection points of the second resistor and the third resistor, and the output end of the first operational amplifier is connected to the fourth resistor and the second transistor. The gate electrode of the second transistor and the gate electrode of the third transistor, the drain electrode of the second transistor and the drain electrode of the third transistor are connected to the energy storage circuit. 2. The backup power operation method of the controller according to claim 1, wherein the charging time of the first charging mode is less than the charging time of the second charging mode. 3. The backup power operating method of the controller according to claim 1, wherein monitoring the input power supply status includes: Determine whether the power supply is output normally based on the input power supply status; The power supply status is normal and the energy storage circuit does not release stored electrical energy; and If the power supply status is abnormal, the energy storage circuit releases the stored electric energy to the controller. 4. The backup power operating method of the controller according to claim 3, wherein the abnormal power supply state includes: The input power supply stops supplying power; Allowing the energy storage circuit to release stored electrical energy to the controller within a discharge condition; and When the discharge condition is met, the energy storage circuit is stopped from releasing stored electric energy to the controller so that the controller is shut down, wherein the discharge condition is related to the release of stored electric energy time. 5. The backup power operating method of the controller according to claim 4, wherein the discharging condition is that the time for releasing the stored electric energy is less than the total time for releasing the stored electric energy of the energy storage circuit. 6. The backup power operating method of the controller according to claim 1, wherein the monitoring step is performed by the backup power supply device, and the backup power supply device includes: A judgment circuit is connected to the input power supply and the first charging module, and is used to monitor the power supply status of the input power supply, and generate a monitoring result when the input power supply interrupts power supply; A switch circuit is connected to the input power supply and the judgment circuit, and has an output terminal, and is used to allow the energy storage circuit to release stored electric energy to the output terminal based on the monitoring result; and A self-cutting circuit connects the energy storage circuit and the switch circuit, and allows the energy storage circuit to release stored electric energy to the switch circuit when a discharge condition is not met based on the monitoring result, and when the discharge condition is met When, the energy storage circuit is stopped to release the stored electric energy. 7. The backup power operation method of the controller according to claim 6, wherein the judgment circuit includes a fifth resistor, a sixth resistor, a seventh resistor and a second operational amplifier, the fifth resistor is connected to the The input power is connected in series with the sixth resistor, the reverse end of the second operational amplifier is connected to the input power, and the forward input end of the second operational amplifier is connected to a series of the fifth resistor and the sixth resistor. The connection point, the seventh resistor is connected to the output end of the second operational amplifier and the energy storage circuit, the output end of the second operational amplifier is connected to the first charging module; the switch circuit includes a fourth transistor and a fifth transistor , the drain of the fourth transistor and the drain of the fifth transistor are connected to the output terminal, the source of the fourth transistor is connected to the input power supply, and the gate of the fourth transistor is connected to the output terminal of the second operational amplifier; The self-cutting circuit includes a relay, an eighth resistor, a ninth resistor and a diode. The relay is connected to the source of the fifth transistor, the energy storage circuit, the eighth resistor, the ninth resistor and the diode. The cathode, the ninth resistor is connected to the energy storage circuit, the anode of the diode is connected to the gate of the fifth transistor and the input power supply, and the discharge condition is related to the relay.