TWI665849B - Controller backup power operation method - Google Patents

Abstract

The operating method of the backup power source of the controller of the present invention includes: starting to supply power through an input power source. Then, a charging procedure is executed to charge the energy storage circuit to a voltage threshold in a first charging mode, and switch to a second charging mode when the voltage threshold is reached to continue charging the energy storage circuit to a full voltage value. The first charging mode starts from the maximum current value and gradually decreases the current value. The second charging mode is a fixed current value and is smaller than the maximum current value. Then, pause the charging procedure. After that, the input power supply status is monitored, and when the input power supply is interrupted, the stored energy is released to the controller through the energy storage circuit. The invention can charge efficiently to ensure that the energy storage circuit is fully charged, and to compensate the power supply in time when the power supply is interrupted to avoid setting or data loss.

Description

Controller backup power operation method

The present invention relates to a power supply system of a controller, and particularly to a method for operating a backup power supply of a controller.

The controller is 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 grasping. The controller is completed by programs or instructions. Various itineraries and operations.

The controller usually needs to perform various strokes and operations through electrical energy. When the power is continuously and stably supplied, the controller can normally perform various strokes and operations. However, if the controller suddenly loses power during execution due to sudden interruption of power and instantaneous drop, etc., it will often cause obvious errors in subsequent trips or operations. For example, when a controller controls a mechanical device to perform a rotational motion, the electrical energy is suddenly interrupted during the rotational stroke, which causes the controller to temporarily lose power. After that, the rotational stroke usually completes a significant deviation. The drift phenomenon is generally caused by the failure of the power interruption time controller to effectively store the current execution state or data and cause subsequent problems.

Therefore, the controller usually needs a backup power supply system that is sufficient to provide the same voltage value as the input power voltage to compensate for the sudden interruption of power. At present, the backup power supply system is usually through a DC / DC converter or linear stabilization. Voltage regulator (LDO), etc. to charge energy storage components, but there are voltage drops in DC / DC converters or linear regulators. Therefore, this charging method The formula usually cannot effectively charge the energy storage element to the same level as the input power voltage, and the charging current will prolong the power-on time as the voltage value decreases.

In addition, because the backup power supply will compensate when the power is shut down or power is interrupted, the discharge time of the backup power supply will also prolong the shutdown time of the controller or system, which will affect the waiting time for shutdown or restart.

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

In order to achieve the above object, the method for operating a backup power supply of the controller of the present invention includes: firstly supplying power through an input power supply. Then, a charging procedure is executed to charge the energy storage circuit to a voltage threshold in a first charging mode, and switch to a second charging mode when the voltage threshold is reached to continue charging the energy storage circuit to a full voltage value. The first charging mode starts from the maximum current value and gradually decreases the current value. The second charging mode is a fixed current value and is smaller than the maximum current value. Then, pause the charging procedure. After that, the input power supply status is monitored, and when the input power supply is interrupted, the stored energy is released to the controller through the energy storage circuit.

In this way, the method for operating the standby power supply of the controller of the present invention can achieve efficient charging of 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 status of the input power supply, the interrupted input power supply can be compensated in time to avoid setting or data loss.

10‧‧‧Process

11-19, 191-196‧‧‧ steps

30‧‧‧ Backup power supply device

31‧‧‧Judgment circuit

33‧‧‧Current Management Circuit

331‧‧‧The first charging module

333‧‧‧Second Charging Module

335‧‧‧Switch Module

35‧‧‧energy storage circuit

37‧‧‧Switch circuit

371‧‧‧output

39‧‧‧ Self-break circuit

391‧‧‧Relay

393‧‧‧Normally open contact

395‧‧‧Common Contact

50‧‧‧ input power

60‧‧‧controller

Q1‧‧‧First transistor

Q2‧‧‧Second transistor

Q3‧‧‧Third transistor

Q4‧‧‧Fourth transistor

Q5‧‧‧Fifth transistor

R1‧‧‧first resistor

R2‧‧‧Second resistor

R3‧‧‧Third resistor

R4‧‧‧Fourth resistor

R5‧‧‧Fifth resistor

R6‧‧‧sixth resistor

R7‧‧‧seventh resistor

R8‧‧‧eighth resistor

R9‧‧‧ Ninth Resistor

D1‧‧‧diode

OPA1‧‧‧First Operational Amplifier

OPA2‧‧‧Second Operational Amplifier

V _in ‧‧‧ input voltage

Vsc‧‧‧ Energy Storage Voltage

V ₂₃ 、 V ₈₉ ‧‧‧ divided voltage

FIG. 1 is a flowchart of a method for operating a standby power supply of a controller of the present invention.

Fig. 2 is an optional flowchart which is continued from Fig. 1;

Fig. 3 is an optional flowchart which is continued from Fig. 2;

Fig. 4 is a block diagram of a standby power operation device of the controller of the present invention.

Fig. 5 is a circuit diagram of a standby power operation device of the controller of the present invention.

FIG. 6 is an operation timing chart of the standby power operation device in FIG. 5.

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

As shown in FIG. 1, this figure is a flowchart of the operation method of the present invention. The operation method of the backup power supply device of the present invention shows four steps, but this is not a limitation on the present invention. In other embodiments, the order of the steps may be changed, or there may be more or fewer steps.

The flow 10 of the method for operating the backup power supply device of the present invention starts from the power supply 11 through the input power. The input power can be DC or AC. The input power in this embodiment is a DC voltage of 24 volts (V). Other embodiments can be Other voltage values. This step can represent just starting up or power interruption, recovery or other states. Input power supply refers to supplying power to the controller and power supply device.

Then, step 13 is to charge the energy storage circuit to a voltage threshold in the first charging mode. The first charging mode starts with an approximate maximum current value and gradually decreases the charging current value. Generally speaking When the controller is powered on, the current drawn by the controller or system is the smallest. Therefore, the energy storage circuit can be charged with the maximum current at this time to shorten the charging time.

Then, step 13 and step 15 switch to the second charging mode when the voltage threshold is reached, so as to continue charging the energy storage circuit to the full voltage value. The second charging mode uses a fixed current value for charging, and the fixed current value is smaller than the maximum current value. Charging with a fixed current can ensure that the energy storage circuit is fully charged. The charge voltage value is charged to a voltage value that is approximately equal to the input voltage, which can be more than, equal to, or slightly less than. Among them, step 13 and step 15 can be integrated into one step, that is, the charging procedure is performed. In other embodiments, the order of the two steps can also be exchanged.

Thereafter, executing step 17 is to suspend the execution of the charging procedure, that is, to pause steps 13 and 15. Step 17 indicates that the energy storage circuit has reached the full voltage value, and the charging of the energy storage circuit is stopped.

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), data storage has been completed and data loss is avoided . Generally speaking, the input power supply is continuous. Interruption occurs only when the power is shut down, power is cut off, or the battery is disconnected. Therefore, interruption refers to the discontinuity of power due to the aforementioned factors or other factors, but the interruption may also occur. It suddenly returned to normal power supply after disappearing suddenly.

In this embodiment, the energy storage circuit includes a supercapacitor. In addition to having a good energy storage capacity, the supercapacitor can also quickly release stored electrical energy, timely compensate for temporarily interrupted power, and maintain the 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 supercapacity capabilities.

Because, in this embodiment, charging is performed through the first charging mode with a larger current value, and then the charging is continued in the second charging mode with a constant current. Therefore, the energy storage circuit can be filled faster than the conventional technology.

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

Continuing the description of FIG. 1, the additional steps of the present invention are shown in FIG. 3. FIG. 3 is a flowchart of a third embodiment of the operating method of the present invention. The third embodiment includes optionally adding step 19 to two other steps to complete the normal shutdown function. Step 194 is to stop the power supply from the input power source, and continue to step 195 to allow the energy storage circuit to release the stored electric energy to the controller during the discharge condition. Next, step 196 is to stop the power supply from the energy storage circuit to the controller when the discharge condition is satisfied. So that the controller is shut down. The discharge condition is related to the time to release the electrical energy. In this embodiment, the discharge condition is that the time to release the stored electrical energy is less than the total time to release the stored electrical energy by 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 efficiently stored and shut down.

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

The steps of executing the charging procedure, suspending the execution of the charging procedure, and monitoring the power supply status of the input power described in steps 13-19 are performed through a backup power supply device. As shown in FIGS. 4 and 5, the backup power supply device 30 includes a determination circuit 31, a current management circuit 33, an energy storage circuit 35, a switch circuit 37, and a self-break circuit 39. The determination circuit 31 is connected to an input power source 50, a current management circuit 33, and a 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-break circuit 39. The self-break circuit 39 is connected to the switch circuit 37. The switching 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 magnitude of the charging current, that is, to select the first charging mode and the second charging mode. Corresponding to FIG. 1 are steps 13 (execute the charging procedure) and step 17 (suspend the execution of the charging procedure).

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 for fixing a 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 source 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, and a third resistor. R3, a fourth resistor R4, and a first operational amplifier OPA1.

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 arbitrary. Therefore, the number of capacitors of the energy storage circuit 35 is not described in this embodiment. Limited.

The gate of the first transistor Q1 is connected to the output of the determination circuit 31. The source of the first transistor Q1, the second resistor R2, and the input terminal of the constant current circuit of the second charging module 333 are connected to the input power source 50 (refer to the symbol Vin). The drain of the first transistor Q1 is connected to the first resistor R1. First resistor R1 another Terminate 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 point of the second resistor R2 and the third resistor R3. The other end of the third resistor R3 is grounded. The inverting input terminal of the first operational amplifier OPA1 is connected to the energy storage circuit 35 (reference symbol Vsc). The output 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 fourth resistor R4. The other end of the fourth resistor R4 is connected to the energy storage circuit 35 (see 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. 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 timing chart of the backup power supply device. When starting up, referring to area A in FIG. 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, the third transistor Q3 is turned on, and the second transistor is turned on. 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, the charging is performed in the first charging mode. In other embodiments, the first transistor Q1 may be omitted.

The voltage threshold is that the divided voltage V ₂₃ of the second resistor R2 and the third resistor R3 is related to the stored voltage Vsc of the energy storage circuit 35. When the divided voltage V _{23 is} lower than the stored voltage Vsc, the first operational 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 a set voltage threshold, the output of the first operational amplifier OPA1 is low, the second transistor Q2 is turned on, and the third transistor When Q3 is turned off, 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, in the second charging mode. Electricity to charge the energy storage circuit 35. in this way. According to 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 efficient charging.

Please refer to FIGS. 5 and 6 continuously. The judgment circuit 31, the switch circuit 37, and the self-break circuit 39 monitor the power supply state of the input voltage V _{in of the} input power source 50 (step 19), and the judgment circuit 31 is used to monitor the input of the input power source 50. Whether the voltage V _in power supply is normally output to generate a monitoring result (step 191). The monitoring result includes normal power supply (step 193) or interruption of power supply (steps 194-196). The switch circuit 37 controls whether the energy storage circuit 35 releases the stored electric energy according to 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 an interruption. When power is supplied, the switch circuit 37 controls the energy storage circuit 35 to release the stored energy to the output terminal 371 to the controller (step 195). The self-break circuit 39 is when the monitoring result of the switching circuit 37 belongs to the power interruption (steps 194-196), first let the energy storage circuit 35 release the stored electric energy to the controller within the discharge condition, and stop when the discharge condition is satisfied The energy storage circuit 35 releases the stored electrical energy to the controller, so that the controller is turned off.

The determination circuit 31 includes a fifth resistor R5, a sixth resistor R6, a seventh resistor R7, and a second operational amplifier OPA2. The input power source 50 is connected to the fifth resistor R5, the inverting input terminal of the second operational amplifier OPA2, and its power source terminal. The forward input terminal of the second operational amplifier OPA2 is connected to the voltage-dividing contact point of the fifth resistor R5 and the sixth resistor R6 connected in series, and the other end of the sixth resistor R6 is grounded. 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 resistor R7, and the switching circuit 37 (as indicated by the symbol Vc in the figure). The other end of the seventh resistor R7 is connected to the energy storage circuit 35 (as shown by the symbol Vsc in the figure).

The switching 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 (reference symbol Vc) of the second operational amplifier OPA2, its source is connected to the input power source 50, and its drain is connected to the output terminal 371, that is, connected to the controller or system. Gate of fifth transistor Q5 The input power source 50 and the self-break circuit 39 are connected. The source is connected to the self-break 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 a PMOS, and the fifth transistor Q5 is a PMOS.

The self-break 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 diode D1. cathode. The other end of the eighth resistor R8 is grounded, 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 voltage V _in . Among them, the relay 391 performs control according to the divided voltage V ₈₉ between the eighth resistor R8 and the ninth resistor R9.

When the input power supply 50 is normally powered, referring to area C of FIG. 6, the second operational amplifier OPA2 outputs a low potential, the first transistor Q1 and the fourth transistor Q4 are turned on, and the controller or system voltage is provided by the input power source 50. At this time, the fifth transistor Q5 is turned off, 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 and its normally open contact 393 are connected, indicating that the energy storage circuit 35 passes through the relay 391 is connected to the fifth transistor Q5. The cut-off voltage value of the relay 391 is determined according to its specifications, and is well known in the industry, which is not described in detail here. Although the energy storage circuit 35 has been able to release the stored electrical energy to the relay 391, the fifth transistor Q5 has not been turned on, so the released stored electrical energy will not be supplied to the output terminal 371.

When the input power 50 is turned off, referring to the D area in FIG. 6, the diode D1 is turned 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 relay 391 and the fifth power The conducting path of the crystal Q5 releases the stored electric energy to the output terminal 371, that is, to supply power to the controller or the system.

When the energy storage circuit 35 drops the energy storage voltage Vsc due to power supply to the controller or the system, 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. When an open path is formed with the energy storage circuit 35, 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 the stored electric energy to the switching circuit 37 is disconnected. In other embodiments, the discharge condition may also be achieved through timing or other methods, without limiting the cut-off voltage value of the relay 391.

In this way, in addition to the method of operating the backup power supply of the controller of the present invention, in addition to efficiently charging the energy storage circuit, it can more effectively ensure that various settings or data are stored before shutdown, and the time for which the energy storage circuit releases electrical energy will not be extended. Off time.

Claims (9)

A method for operating a controller's standby power source includes: 开始 starting power supply through an input power source; executing a charging procedure to charge an energy storage circuit to a voltage threshold in a first charging mode, and switching when the voltage threshold is reached To a second charging mode to continue charging the energy storage circuit to a full-charge voltage value, the first charging mode starts from the maximum current value and gradually decreases the current value, the second charging mode is a fixed current value, and Less than the maximum current value; suspend execution of the charging process; and monitor the input power supply status, and release the stored power to the controller through the energy storage circuit when the input power supply is interrupted. The method for operating a backup power supply of a controller according to item 1 of the scope of patent application, wherein the charging time in the first charging mode is shorter than the charging time in the second charging mode. The backup power supply operation method of the controller according to item 1 of the scope of patent application, wherein monitoring the input power supply status includes: 判断 judging whether the power supply is normally output according to the input power supply status; the power supply status is normal, the energy storage circuit does not release Stored energy; and the power supply is abnormal, the energy storage circuit releases stored energy to the controller. The method for operating a backup power supply of a controller as described in item 3 of the scope of patent application, wherein the abnormal power supply state includes: 停止 the input power supply stops supplying power; 允许 the energy storage circuit is allowed to release stored electrical energy to the controller within a discharge condition; And when the discharge condition is satisfied, stopping the energy storage circuit from releasing stored electric energy to the controller so that the controller is shut down, wherein the discharging condition is related to the time when the stored energy is released. The method for operating a backup power supply of a controller according to item 4 of the scope of patent application, wherein the discharge condition is that the time for releasing the stored energy is less than the total time for releasing the stored energy by the energy storage circuit. According to the method for operating a backup power supply of a controller according to item 1 of the scope of patent application, wherein the execution and suspension steps are performed by a backup power supply device, the backup power supply device includes: (1) a current management circuit, including a first A charging module, a second charging module, and a switching module; the first charging module is connected to the input power; the second charging module is connected to the input power; the switching module is connected to the input power; A 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 first charging mode A charging mode and the second charging mode. The method for operating a backup power supply of a controller according to item 6 of the scope of patent application, wherein the first charging module includes a first transistor and a first resistor; the second charging module includes a certain current circuit; the switching The module includes a second transistor, 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. The circuit is connected to the input power source, the first resistor is connected to the source of the third transistor, the constant current circuit is connected to the source of the second transistor, the second resistor and the third resistor are connected in series, and the fourth resistor is connected in series. A resistor is connected to the energy storage circuit, a reverse input terminal of the first operational amplifier is connected to the energy storage circuit, and a forward input terminal of the first operational amplifier is connected to a series of connection points of the second resistor and the third resistor. The output terminal of the first operational amplifier is connected to the fourth resistor, the gate of the second transistor and the gate of the third transistor, and the second transistor drain and the third transistor drain are connected to the energy storage circuit. . According to the backup power supply operating method of the controller according to item 6 of the scope of patent application, wherein the monitoring step is performed by the backup power supply device, the backup power supply device includes: (1) a judgment circuit connected to the input power supply and the first A charging module is used to monitor the power supply state of the input power source and generate a monitoring result when the input power source is interrupted; (1) a switching circuit connected to the input power source and the judgment circuit, and has an output terminal, and is used for The monitoring result allows the energy storage circuit to release the stored electric energy to the output terminal; and a self-disconnecting circuit connected to the energy storage circuit and the switching circuit, and allowing the energy storage to be performed when a discharge condition is not satisfied according to the monitoring result The circuit releases the stored electrical energy to the switching circuit, and stops the energy storage circuit from releasing the stored electrical energy when the discharge condition is satisfied. The method for operating a backup power supply of a controller according to item 8 of the scope of patent application, wherein the judging circuit includes a fifth resistor, a sixth resistor, a seventh resistor, and a second operational amplifier, and the fifth resistor is connected The input power is connected in series with the sixth resistor, the reverse terminal of the second operational amplifier is connected to the input power, and the forward input of the second operational amplifier is connected to one of the fifth resistor and the sixth resistor. A series connection point, the seventh resistor is connected to the output terminal of the second operational amplifier and the storage circuit, and the output terminal of the second operational amplifier is connected to the first charging module; the switch circuit includes a fourth transistor and a first Five transistors, 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 source, and the gate of the fourth transistor is connected to the second transistor. Output terminal of the operational amplifier; the self-break 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, and the eighth resistance, The ninth resistor and the cathode of the diode, the ninth transistor 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 source, and the discharge condition is related to the relay .