WO2023207279A1 - 一种数字量输出回路断线诊断装置及诊断方法 - Google Patents

一种数字量输出回路断线诊断装置及诊断方法 Download PDF

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Publication number
WO2023207279A1
WO2023207279A1 PCT/CN2023/077133 CN2023077133W WO2023207279A1 WO 2023207279 A1 WO2023207279 A1 WO 2023207279A1 CN 2023077133 W CN2023077133 W CN 2023077133W WO 2023207279 A1 WO2023207279 A1 WO 2023207279A1
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mos switch
stage mos
stage
disconnection
detection module
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PCT/CN2023/077133
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English (en)
French (fr)
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刘铭皓
李越
于金生
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南京科远智慧科技集团股份有限公司
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Publication of WO2023207279A1 publication Critical patent/WO2023207279A1/zh

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/50—Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections
    • G01R31/54—Testing for continuity
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/50—Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections
    • G01R31/58—Testing of lines, cables or conductors

Definitions

  • the invention relates to cable circuit diagnosis and implementation methods for digital output loops in automation products.
  • this application provides a digital output circuit disconnection diagnosis device and diagnosis method, which can detect cable disconnection faults in a timely manner when the external load is powered on or off.
  • This technology uses switches. Quantity detection, low cost, and can meet application requirements in situations with a large load variation range.
  • a digital output circuit breakage diagnostic device including:
  • the DC power supply outputs the positive power voltage and drive current through the front-stage MOS switch and the rear-stage MOS switch in turn;
  • the external load is connected to the cable to be diagnosed, The drive current returns to ground after passing through the load;
  • the controller sends out a high or low level control signal and controls the closing and closing of two series-connected MOS switches through the corresponding signal isolator;
  • the disconnection detection module is connected in parallel with the front-stage MOS switch and outputs digital signals to the controller.
  • the positive terminal of the DC power supply is connected to the s pole of the front-stage MOS switch
  • the d pole of the MOS switch is connected to the s pole of the subsequent-stage MOS switch
  • the d-pole of the latter-stage MOS switch is connected to the diagnosed cable and outputs the positive voltage of the power supply.
  • the driving current the external load is connected to the diagnosed cable, the driving current flows into the load from the positive terminal of the load, flows out from the negative terminal of the load and returns to ground;
  • the output IO port of the controller is connected to the input end of the signal isolator and sends a high or low level control signal to the signal isolator.
  • the output ends of the two signal isolators are connected to the g poles of the two MOS switches respectively; the disconnection detection module Connected to the s pole and d pole of the front-stage MOS switch, the disconnection detection module outputs a digital signal to the IO port of the controller.
  • the power supply is 24V DC or 48V DC.
  • the two MOS switches are PMOS.
  • the MOS switches When the gate and source voltages of the MOS switches are 0, the MOS switches are turned off; when the gate and source voltages of the MOS switches are less than 0, the MOS switches are turned on; control
  • the controller controls the closing or closing of the downstream MOS switch, and correspondingly enables the load to gain or lose power.
  • the controller controls the front-stage switch to close or turn off, and the disconnection detection module outputs an identification signal to the controller input port.
  • the key component is an optocoupler.
  • the input end of the optocoupler is connected in series with a current limiting resistor and is connected in parallel with the s pole and d pole of the front-stage MOS switch.
  • the output end of the optocoupler is connected to the control Connect to the input IO port of the device.
  • the signal isolator is an optical coupler.
  • the input end of the optocoupler is connected to the controller output IO port.
  • the output end of the optocoupler is connected to the g pole of the MOS switch.
  • This application also provides a digital output loop disconnection diagnosis method, including:
  • the controller controls the front-stage MOS switch K1 and the rear-stage MOS tube K2 to remain closed, and the output of the disconnection detection module U4 is turned off. During the diagnosis process, the controller controls K1 to turn off and close regularly. If the external cable is normal, U4 will output the closing and shutdown signals to the controller input port accordingly. If the external cable is disconnected, U4 will constantly output the shutdown signal.
  • the turn-off duration of K1 is very short, less than 2ms, and will not affect the normal operation of the load;
  • the controller controls K1 and K2 to remain disconnected, and the output of the disconnection detection module U4 is turned off.
  • the controller controls K2 to turn off and close regularly. If the external cable is normal, U4 will correspondingly output the turn-off and close signals to the controller input port. If the external cable is disconnected, U4 will constantly output a turn-off signal.
  • the duration of K2 closing is very short, less than 2ms, and will not affect the normal operation of the load.
  • the beneficial effect of this application is that when the equipment is working, the cable can be diagnosed online continuously and regularly, and no matter the external load is working in a power-on or power-off state, an alarm can be given in time when a fault occurs.
  • the detection device provided has a wide applicable external load range, from 4 mA to 1 A, and the implementation cost is low.
  • Figure 1 is a schematic structural diagram of a diagnostic device according to an embodiment of the present application.
  • FIG. 2 is a detailed schematic diagram of the signal isolator U2 or U3 in Figure 1;
  • FIG. 3 is a detailed schematic diagram of the interrupt line detection module U4 in FIG. 1 .
  • a digital output circuit disconnection diagnostic device includes a DC power supply Vcc, a controller U1, a signal isolator U2 and a signal isolator U3, a front-stage PMOS switch K1, a rear-stage PMOS switch K2, and a wire breakage device.
  • the detection module U4 performs cable breakage diagnosis by connecting to the diagnosed cable and the external load R.
  • signal isolator U2 or signal isolator U3 uses an optocoupler.
  • the positive input terminal is connected to the IO port of the controller, and the negative input terminal is connected to the ground of controller U1.
  • the negative terminal of the output is connected to the ground of the DC power supply Vcc.
  • the positive terminal of the output is connected to two series-connected resistors R3 and R4, and then connected to the positive terminal of the DC power supply.
  • the connection of the two series resistors (R3 and R4) is connected to the g pole of the corresponding PMOS switch. As the optocoupler turns on and off, the voltage of Vg changes.
  • the wire break detection module U4 includes the key component optocoupler K3.
  • the positive end of the input side of K3 is connected to the current limiting resistor R2 with a resistance of 2K ⁇ .
  • the other end of R2 is connected to the s pole of the front-stage MOS switch K1.
  • K3 input The negative terminal on the side is connected to the d pole of the front-stage MOS switch K1.
  • the input sides of K1 and K3 form a parallel relationship.
  • the negative terminal of the output side of K3 is connected to the ground of the controller U1, the positive terminal of the output side is connected to the pull-up resistor R1, and it is input to the IO port of the controller.
  • the pull-up resistor is connected to the positive terminal of the controller power supply.
  • the input side current of the optocoupler K3 must be in the range of 1mA to 50mA before it can be turned on normally, and when it is turned on, the internal diode voltage drop at the input end of K3 is about 1V.
  • the on-resistance of the front-stage MOS switch is 0.1 ⁇ .
  • the current-limiting resistor R2 on the input side of K3 is 2K ⁇ , the minimum conduction current is 1mA, and the maximum voltage drop of the front-stage MOS switch is only 0.1V, and the voltage drop of the diode at the input side of K3 is not included, so the current on the input side of K3 is much less than 1mA. , the output side is turned off.
  • the load design of the detection device allows the current range to be 4mA ⁇ 1A, the DC power supply voltage is 24V or 48V, and the load resistance range is 24 ⁇ 6K ⁇ or 48 ⁇ 12K ⁇ .
  • the controller controls the front-stage MOS switch K1 to turn off, and the rear-stage MOS switch K2 to remain closed: when the DC power supply is 24V, the current range of the K3 input side is about 3mA to 12mA; when the DC power supply is 48V, the current range of the K3 input side is about 6mA. to 24mA, all within the input current range when K3 is turned on, meeting the output conduction requirements of K3, and can complete the disconnection diagnosis function.
  • the controller controls the rear-stage MOS tube K2 to remain closed, and controls K1 to turn off and close regularly; when the external load is normally powered, the controller The controller controls K1 to remain open, and the controller controls K2 to turn off and on periodically.
  • U4 will output the closing and shutdown signals to the controller input port accordingly; if the external cable is disconnected, U4 will constantly output the shutdown signal.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Testing Of Short-Circuits, Discontinuities, Leakage, Or Incorrect Line Connections (AREA)
  • Arrangements For Transmission Of Measured Signals (AREA)

Abstract

一种数字量输出回路断线诊断装置，包括：直流电源；两个串联的MOS开关，前级MOS开关K1和后级MOS开关K2；直流电源依次通过前级MOS开关和后级MOS开关后输出电源正电压和驱动电流；外部负载与待诊断线缆相连，驱动电流经负载后回到地；控制器，发出高或低电平控制信号，通过对应的信号隔离器分别控制两个串联的MOS开关的闭合和关断；断线检测模块，与前级MOS开关并联，输出数字信号至控制器。采用该诊断装置，在外部负载得电或者失电状态时，都能够及时地检测出线缆断线故障，且该技术采用开关量检测，成本较低，可满足负载变化范围较大的应用。

Description

一种数字量输出回路断线诊断装置及诊断方法 技术领域
本发明涉及自动化产品中数字量输出回路的线缆电路诊断和实现方法。
 背景技术
工业自动化生产应用中，DCS和PLC产品被大量使用，其中的数字量输出模件若要能够正常的输出信号驱动设备，线缆断线诊断必不可少。传统的数字量输出线缆诊断方案使用串联的检流电阻，将回路的电流信号差分采集给模数转换器，或者转换成电压信号给比较器判断识别。
但是当外部负载变化范围较大时，回路中的电流变化范围也会很大，为了保证诊断功能正常工作，需要使用高精度器件完成识别，硬件成本大大提升。
 发明内容
为了解决上述问题，本申请提供一种数字量输出回路断线诊断装置及诊断方法，在外部负载得电或者失电状态时，都能够及时地检测出线缆断线故障，且该技术采用开关量检测，成本较低，可满足在负载变化范围较大场合的应用要求。
本申请提供的技术方案如下：
一种数字量输出回路断线诊断装置，包括：
直流电源；
两个串联的MOS开关，前级MOS开关K1和后级MOS开关K2；直流电源依次通过前级MOS开关和后级MOS开关后输出电源正电压和驱动电流；外部负载与待诊断线缆相连，驱动电流经负载后回到地；
   控制器，发出高或低电平控制信号，通过对应的信号隔离器分别控制两个串联的MOS开关的闭合和关断；
   断线检测模块，与前级MOS开关并联，输出数字信号至控制器。
更具体的，直流电源的正端连接前级MOS开关的s极，该MOS开关的d极连接后级MOS开关的s极，后级MOS开关的d极连接被诊断线缆并输出电源正电压和驱动电流，外部负载与被诊断线缆相连，驱动电流由负载的正端流入负载，由负载的负端流出并回到地；
控制器的输出IO端口连接信号隔离器的输入端并向信号隔离器发出高或低电平控制信号，2个信号隔离器的输出端分别和2个MOS开关的g极相连；断线检测模块与前级MOS开关的s极和d极相连，断线检测模块输出数字信号到控制器的IO端口。
进一步地，所述电源为直流24V或直流48V。
进一步地，所述2个MOS开关都为PMOS，MOS开关的栅极和源极电压为0时，MOS开关关断；MOS开关的栅极和源极电压小于0时，MOS开关导通；控制器控制后级MOS开关闭合或关断，并对应使得负载得电或失电。后级开关保持闭合时，控制器控制前级开关闭合或关断，断线检测模块输出识别信号给控制器输入端口。
进一步地，所述断线检测模块中，关键器件为光耦合器，光耦合器输入端串联限流电阻后与前级MOS开关的s极和d极并联连接，光耦合器的输出端与控制器的输入IO端口连接。前级和后级MOS开关闭合时，前级MOS开关的压降很小，光耦合器的输入端几乎无电流，光耦合器输出关断。后级MOS开关保持闭合，前级MOS开关关断时，光耦合器有电流流过，光耦合器输出端闭合。
进一步地，所述信号隔离器为光耦合器。光耦合器的输入端与控制器输出IO端口相连。光耦合器的输出端与MOS开关的g极相连。
本申请还提供一种数字量输出回路断线诊断方法，包括：
1）当外部负载正常为得电应用时，控制器控制前级MOS开关K1和后级MOS电管K2保持闭合，断线检测模块U4输出关断。诊断过程中，控制器控制K1定期地关断和闭合，若外部线缆正常，U4对应地输出闭合和关断信号给控制器输入端口,若外部线缆断线，U4恒定输出关断信号。K1关断的持续时间非常短，小于2ms，不会影响负载的正常运行；
2）当外部负载正常为失电应用时，控制器控制K1和K2保持断开，断线检测模块U4输出关断。诊断过程中，控制器控制K2定期地关断和闭合，若外部线缆正常，U4对应地输出关断和闭合信号给控制器输入端口,若外部线缆断线，U4恒定输出关断信号。K2闭合的持续时间非常短，小于2ms，不会影响负载的正常运行。
本申请的有益效果在于：设备工作时，可以在线连续定期地对线缆诊断，无论外部负载工作在得电还是失电状态，均能在故障时及时给出报警。本申请的一个实施例中，所提供的检测装置可适用的外部负载范围较大，可从4mA到1A，且实现的成本较低。
 附图说明
 图1为本申请实施例的诊断装置的结构示意图；
图2为图1中信号隔离器U2或U3的详细示意图；
图3为图1中断线检测模块U4的详细示意图。
 具体实施方式
下面结合附图对本申请技术方案作进一步的说明。
如图1所示，一种数字量输出回路断线诊断装置，包括直流电源Vcc，控制器U1、信号隔离器U2和信号隔离器U3、前级PMOS开关K1、后级PMOS开关K2、断线检测模块U4，通过与被诊断线缆以及外部负载R相连进行线缆断线诊断。
如图2所示，信号隔离器U2或信号隔离器U3，采用光耦合器，输入正端接控制器IO口，输入负端接控制器U1的地。输出负端接直流电源Vcc的地。输出正端接2个串联的电阻R3和电阻R4，再接直流电源正端。2个串联电阻（R3和R4）的连接处接对应的PMOS开关的g极。随着光耦合器的导通和关断，Vg的电压也会变化。
如图3所示，断线检测模块U4包括关键器件光耦合器K3，K3的输入侧正端连接限流电阻R2，阻值2KΩ，R2另一端连接前级MOS开关K1的s极，K3输入侧负端连接前级MOS开关K1的d极。K1与K3的输入侧形成并联关系。K3的输出侧负端接控制器U1的地，输出侧正端接上拉电阻R1，同时输入控制器IO口，上拉电阻接控制器电源正端。
光耦合器K3的输入侧电流范围在1mA到50mA才可正常导通，且导通时K3输入端内部二极管压降约为1V。前级MOS开关的导通阻值为0.1Ω。当回路的2个MOS开关K1、K2都闭合时，负载得电，回路设计最大允许电流为1A。由于K3输入侧的限流电阻R2为2KΩ，导通最小电流1mA，而前级MOS开关最大压降只有0.1V，且未算上K3输入端二极管的压降，所以K3输入侧电流远小于1mA，输出侧关断。
本实施例提供的检测装置负载设计允许电流范围4mA~1A，直流电源电压为24V或48V，负载阻值范围24Ω~6KΩ或48Ω~12KΩ。控制器控制前级MOS开关K1关断，后级MOS开关K2保持闭合：直流电源24V时，K3输入侧的电流范围约为3mA到12mA；直流电源48V时，K3输入侧的电流范围约为6mA到24mA，都在K3导通时的输入电流范围内，满足K3的输出导通要求，可以完成断线诊断功能。
进行线缆诊断时，当外部负载正常为得电应用时，控制器控制后级MOS电管K2保持闭合，并控制K1定期地关断和闭合；当外部负载正常为失电应用时，控制器控制K1保持断开，并控制器控制K2定期地关断和闭合。
若外部线缆正常，U4对应地输出闭合和关断信号给控制器输入端口；若外部线缆断线，U4恒定输出关断信号。
以上所述仅是本发明的一种实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下还可以作出若干改进，这些改进也应视为本发明的保护范围。

Claims (7)

  1. 一种数字量输出回路断线诊断装置，其特征在于，包括：
    直流电源；
    信号隔离器；
    两个串联的MOS开关，前级MOS开关和后级MOS开关；直流电源依次通过前级MOS开关和后级MOS开关后输出电源正电压和驱动电流；外部负载与待诊断线缆相连，驱动电流经负载后回到地；
    控制器，发出高或低电平控制信号，通过对应的信号隔离器分别控制两个串联的MOS开关的闭合和关断；
    断线检测模块，与前级MOS开关并联，输出数字信号至控制器。
  2. 根据权利要求1所述的数字量输出回路断线诊断装置，其特征在于，所述前级MOS开关和后级MOS开关均采用PMOS；当MOS开关的栅极和源极电压为0时，MOS开关关断；当MOS开关的栅极和源极电压小于0时，MOS开关导通；当外部负载为得电应用时，控制器控制后级MOS开关保持闭合，控制前级MOS开关定期闭合和关断；当外部负载为失电应用时，控制器控制前级MOS开关保持关断，并控制后级MOS开关定期闭合和关断；所述控制器控制前级MOS开关或后级MOS开关关断的持续时间小于2ms。
  3. 根据权利要求2所述的数字量输出回路断线诊断装置，其特征在于，所述断线检测模块采用光耦合器，光耦合器的输入端串联限流电阻后与所述前级MOS开关的s极和d极并联连接，光耦合器的输出端与所述控制器的输入IO端口连接。
  4. 根据权利要求3所述的数字量输出回路断线诊断装置，其特征在于，所述信号隔离器均采用光耦合器，光耦合器的输入端与控制器输出IO端口连接，光耦合器的输出端与对应的MOS开关的g级相连。
  5. 根据权利要求4所述的数字量输出回路断线诊断装置，其特征在于，所述直流电源采用直流24V或直流48V。
  6. 根据权利要求5所述的数字量输出回路断线诊断装置，其特征在于，所述断线检测模块的光耦合器串联的限流电阻为2KΩ。
  7. 采用权利要求1所述诊断装置进行数字量输出回路断线诊断的方法，其特征在于，所述诊断方法如下：
              当外部负载正常为得电应用时，控制器控制前级MOS开关和后级MOS开关保持闭合，断线检测模块输出关断；诊断过程中，控制器控制前级MOS开关定期地关断和闭合，通过控制器接收断线检测模块的识别信号进行线缆诊断：当断线检测模块对应输出的闭合和关断信号时，诊断外部线缆正常，当断线检测模块恒定输出的关断信号时，诊断外部线缆断线；
            当外部负载正常为失电应用时，控制器控制前级MOS开关和后级MOS开关保持断开，断线检测模块输出关断；诊断过程中，控制器控制后级MOS开关定期地关断和闭合，通过控制器接收断线检测模块的识别信号进行线缆诊断：当断线检测模块对应输出的闭合和关断信号时，诊断外部线缆正常，当断线检测模块恒定输出的关断信号时，诊断外部线缆断线。
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