Environment monitoring system in explosion-proof motor junction box and potential safety hazard monitoring method

Abstract

The invention discloses an environment monitoring system in an explosion-proof motor junction box and a potential safety hazard monitoring method. The environment monitoring system comprises an environment monitoring sensor, a first processor, a first carrier module, a second carrier module, a second processor, a wireless communication module and a monitoring terminal. The environment information in the junction box is transmitted to the processor of the switch cabinet in a power line carrier mode, and the processor processes the received environment information to obtain environment condition data and sends the environment condition data to the monitoring terminal in a wireless transmission mode. And the monitoring terminal analyzes and processes the environmental condition data, judges whether the junction box has potential safety hazards or not and informs a user of the potential safety hazards. According to the invention, on-line monitoring of the environment in the junction box is realized, a user can timely find and process hidden dangers existing in the junction box during operation or shutdown of the explosion-proof motor, motor faults are avoided, and potential safety hazards of equipment are eliminated. In addition, the explosion-proof structure of the junction box does not need to be changed, and potential safety hazards of transformation construction are eliminated.

Description

Technical Field

[0001] The invention belongs to the technical field of internal environment monitoring of explosion-proof motor junction boxes, and in particular relates to an internal environment monitoring system of explosion-proof motor junction boxes and a safety hazard monitoring method. Background Art

[0002] During the long-term continuous operation of explosion-proof motors, the wiring terminals in the junction box may have heating and overheating problems. Exceeding the allowable limit will cause damage to the motor, affecting the safe and stable operation of the continuous production device. In addition, in order to ensure the stable operation of the continuous production device, spare motors are generally configured for important running motors. Long-term shutdown may cause moisture to invade the spare explosion-proof motor junction box, resulting in condensation of water vapor. Before starting the spare explosion-proof motor, if the environmental conditions in the box (such as humidity and temperature data) are not monitored, the explosion-proof motor junction box may malfunction during the operation of the motor, resulting in accidents and affecting the user's safe production.

[0003] The explosion-proof motor junction box is an iron sealed structure, which is large and bulky. The use site is an explosion-proof area, and it is inconvenient to disassemble the junction box on site. For some chemical production equipment, it is not allowed to be disassembled and inspected at will during production. Maintenance personnel cannot grasp the status of the explosion-proof motor junction box in time, resulting in hidden dangers in the operation process.

[0004] In order to solve the above problems, there is a technology that uses wireless data transmission to transmit data in the junction box to the outside. In this type of solution, a sensor with wireless data transmission needs to be placed in the explosion-proof motor junction box. However, since the junction box is a sealed iron shell, the wireless signal will be shielded. Therefore, the existing explosion-proof motor junction box outlet cable gland needs to be equipped with a radio frequency antenna. Although this approach can lead the signal to the outside of the junction box for reception, it also changes the original explosion-proof sealing structure, which poses hidden dangers and risks.

[0005] In addition, existing monitoring systems often require additional power supplies, which increases the complexity of the system and the difficulty of installation. At the same time, how to continuously monitor the environment inside the junction box when the motor is stopped is also an urgent problem to be solved.

[0006] In view of the above problems, the existing technology needs to be improved urgently. Summary of the invention

[0007] The purpose of the present invention is to provide an explosion-proof motor junction box environment monitoring system and a safety hazard monitoring method, by using a power line carrier to transmit the temperature and humidity data measured in the explosion-proof motor junction box to the outside, without changing the existing explosion-proof structure of the junction box, to achieve online monitoring of the environment inside the explosion-proof motor junction box, so as to discover the hidden dangers of the junction box in advance.

[0008] The present invention is implemented as follows: an environment monitoring system in an explosion-proof motor junction box includes an environment monitoring sensor, a first processor and a first carrier module located in the junction box; and a second carrier module, a second processor and a wireless communication module located in a switch cabinet;

[0009] The environmental monitoring sensor is used to measure environmental information in the junction box and send the measured environmental information to the first processor;

[0010] The first processor is used to convert the environmental information into a digital signal and send it to the first carrier module, and the first carrier module modulates the digital signal into a carrier signal and couples it to the power cable of the motor;

[0011] The second carrier module is used to receive a carrier signal from the power cable, demodulate the carrier signal into a digital signal, and send it to the second processor;

[0012] The second processor is used to process the received digital signal to obtain environmental status data, and send the environmental status data to the monitoring terminal in a wireless transmission manner through the wireless communication module;

[0013] The monitoring terminal is used to determine whether there is a potential safety hazard in the junction box after processing and analyzing the environmental condition data, and inform the user through sound and / or display.

[0014] Furthermore, the environmental monitoring system further comprises a voltage sampling module, a battery and a power processing module located in the junction box, the voltage sampling module is connected to the motor terminal, and is used to sample the voltage on the motor terminal, and send the sampled voltage information to the first processor, the first processor calculates the sampled voltage value, and determines the current state of the motor;

[0015] When the motor is in operation, the first processor controls the power processing module to obtain power from the motor terminal, and the power processing module performs AC-DC conversion and voltage high-low conversion on the obtained electric energy, and then supplies power to the environment monitoring sensor, the first processor and the first carrier module;

[0016] When the motor is in a stopped state, the electric energy of the battery is converted into voltage by the power processing module to power the environment monitoring sensor, the first processor and the first carrier module to maintain continuous operation of environment monitoring and data transmission.

[0017] Furthermore, the battery is a rechargeable battery. When the motor is in operation, the power processing module performs AC-DC conversion and voltage high-low conversion on the acquired electric energy and then charges the battery.

[0018] Furthermore, the voltage sampling module is a resistor voltage division sampling circuit.

[0019] Furthermore, the environment monitoring sensor includes a temperature measurement sensor and a humidity measurement sensor, the temperature measurement sensor is used to measure the temperature in the junction box, and the humidity measurement sensor is used to measure the humidity in the junction box.

[0020] To achieve the above-mentioned purpose, the present invention also provides a method for monitoring safety hazards in the environment of an explosion-proof motor junction box, comprising the following steps:

[0021] Obtain environmental information inside the explosion-proof motor junction box;

[0022] The environmental information is converted into a digital signal, the digital signal is modulated into a carrier signal by a first carrier module, and then coupled to a power cable of the motor;

[0023] Transmitting the carrier signal to the contactor outlet of the switch cabinet via a power cable in a power carrier mode;

[0024] The received carrier signal is converted into a digital signal by the second carrier module and sent to the processor, and the processor processes the received digital signal to obtain the environmental status data in the explosion-proof motor junction box;

[0025] Send environmental status data to the monitoring terminal by wireless transmission;

[0026] The monitoring terminal analyzes and processes the environmental status data to determine whether there is a potential safety hazard in the explosion-proof motor junction box, and notifies the user of the determination result by display and / or voice.

[0027] Furthermore, the potential safety hazard monitoring method further comprises the following steps:

[0028] Preset a reasonable temperature range and a reasonable humidity range in the monitoring terminal; compare the measured temperature with the preset reasonable temperature range to determine whether the temperature in the junction box is normal; compare the measured humidity with the preset reasonable humidity range to determine whether the humidity in the junction box is normal;

[0029] When at least one of the temperature or the humidity in the junction box is abnormal, it is determined that there is a safety hazard in the junction box.

[0030] Furthermore, the environmental information obtained includes temperature and humidity in the junction box.

[0031] Furthermore, the potential safety hazard monitoring method further comprises the following steps:

[0032] When the motor is in operation, the battery is charged and the environment monitoring sensor, the first processor and the first carrier module are powered through the power cable of the motor;

[0033] When the motor is in a stopped state, the battery supplies power to the environment monitoring sensor, the first processor and the first carrier module.

[0034] Compared with the prior art, the present invention has the following beneficial effects:

[0035] 1. The present invention transmits the environmental information in the junction box to the switch cabinet through the power carrier technology, and then sends it to the monitoring terminal through wireless transmission to determine the potential safety hazards and then inform the user's maintenance personnel, thereby avoiding the problem of wireless signals being shielded by the iron junction box, and realizing online monitoring of the environment in the junction box. The user maintenance personnel can grasp the environmental changes in the junction box of the explosion-proof motor during operation and shutdown in real time, and deal with abnormalities in time to avoid motor failures caused by excessive temperature or humidity, and eliminate equipment safety hazards.

[0036] 2. The present invention does not need to change the explosion-proof structure of the explosion-proof motor junction box, thereby reducing the risk of transformation and eliminating the safety hazards of transformation construction.

[0037] 3. The present invention can continuously monitor the environmental conditions in the junction box during the shutdown of the explosion-proof motor, effectively avoiding the occurrence of insulation breakdown and damage to the motor during startup due to condensation in the junction box after a long shutdown, thereby ensuring the safe and stable operation of the production equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a structural block diagram of an environment monitoring system inside an explosion-proof motor junction box provided in an embodiment of the present application;

[0039] Figure 2 It is a flow chart of a method for monitoring safety hazards of an explosion-proof motor junction box provided in an embodiment of the present application. DETAILED DESCRIPTION

[0040] The following will be combined with the drawings in the present application to clearly and completely describe the technical solutions in the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. The components of the present application generally described and shown in the drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the present application claimed for protection, but only represents the selected embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without making creative work belong to the scope of protection of the present application. It should be noted that similar reference numerals and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further defined and explained in the subsequent drawings. At the same time, in the description of the present application, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0041] During long-term continuous operation of explosion-proof motors, the wiring terminals in the junction box may heat up or even overheat. Exceeding the allowable limit will cause damage to the motor and affect the safe and stable operation of the production equipment. In addition, for important running motors, spare motors are usually configured, but long-term shutdown may cause moisture to invade the spare explosion-proof motor junction box, resulting in condensation. If the environmental conditions in the box are not monitored before starting the spare explosion-proof motor, a fault may occur during the operation of the motor, affecting the user's safe production.

[0042] For the above problems, please refer to Figure 1 The present embodiment provides an environment monitoring system inside an explosion-proof motor junction box, including an environment monitoring sensor 1, a first processor 2 and a first carrier module 3 located in a junction box 10, and a second carrier module 4, a second processor 5 and a wireless communication module 6 located in a switch cabinet 30, and a monitoring terminal 40.

[0043] The environmental monitoring sensor 1 is used to measure the environmental information in the junction box 10 and send the measured environmental information to the first processor 2. The first processor 2 converts the environmental information into a digital signal and sends it to the first carrier module 3. The first carrier module 3 modulates the digital signal into a carrier signal and couples it to the power cable 20 of the motor. The second carrier module 4 receives the carrier signal from the power cable 20, demodulates the carrier signal into a digital signal, and sends it to the second processor 5. The second processor 5 processes the received digital signal to obtain environmental status data, and sends the environmental status data to the monitoring terminal 40 by wireless transmission through the wireless communication module 6. The monitoring terminal 40 can be a mobile terminal or control background with a display function and / or a voice function. The monitoring terminal 40 is used to determine whether there is a safety hazard in the junction box 10 after analyzing and processing the environmental status data, and inform the user through sound and / or display.

[0044] In this embodiment, the environment monitoring sensor 1 includes a temperature measurement sensor and a humidity measurement sensor, wherein the temperature measurement sensor is used to measure the temperature in the junction box, and the humidity measurement sensor is used to measure the humidity in the junction box. Among them, the temperature measurement sensor can be in the form of a thermocouple, a thermistor or an integrated temperature sensor, and the humidity measurement sensor can be in the form of a capacitive humidity sensor, an impedance humidity sensor or an integrated humidity sensor. Specifically, the thermocouple measures the temperature by generating an electromotive force through a temperature difference, the thermistor measures the temperature by changing the resistance with the temperature, and the integrated temperature sensor integrates the temperature measurement circuit through a semiconductor process. The capacitive humidity sensor measures the humidity by changing the capacitance, the impedance humidity sensor measures the humidity by changing the resistance, and the integrated humidity sensor integrates the humidity measurement circuit through a semiconductor process. Through the combination of these sensors, comprehensive monitoring of the environment in the junction box can be achieved.

[0045] The first carrier module 3 and the second carrier module 4 can be implemented by a variety of technologies, for example, a modem based on power line communication (PLC) technology can be used. The modulation method of the digital signal can also be selected according to the actual situation, for example, amplitude keying (ASK), frequency shift keying (FSK) or phase shift keying (PSK) can be used. The wireless communication method can adopt a variety of wireless communication technologies, such as Wi-Fi, Bluetooth or LoRa, etc., to meet different application scenarios and communication distance requirements. The first processor 2 and the second processor 5 can use a microcontroller or other suitable processing unit for data processing and wireless data transmission.

[0046] This embodiment uses power carrier technology to transmit the temperature and humidity conditions in the junction box 10 to the switch cabinet 30, and then sends it to the monitoring terminal 40 through the wireless communication module 6 for safety hazard determination and then informs the user's maintenance personnel, avoiding the problem of wireless signals being shielded by the iron junction box 10, and it is not necessary to change the explosion-proof structure of the user's on-site explosion-proof motor junction box, thereby reducing the risk of transformation and eliminating safety hazards of transformation construction. At the same time, online monitoring of environmental conditions such as temperature and humidity in the junction box 10 is realized, and maintenance personnel can grasp the environmental changes in the junction box of the explosion-proof motor in real time during operation and shutdown, avoiding motor failures caused by excessive temperature or humidity, and eliminating equipment safety hazards.

[0047] Furthermore, the monitoring system of this embodiment further includes a voltage sampling module 7 , a battery 8 and a power processing module 9 located in the junction box 10 .

[0048] The voltage sampling module 7 is connected to the motor terminal, and is used to sample the voltage on the motor terminal, and send the sampled voltage information to the first processor 2. The first processor 2 calculates the sampled voltage value and determines the current state of the motor.

[0049] In this embodiment, the voltage sampling module 7 adopts a resistor voltage-dividing sampling circuit. The basic principle of the resistor voltage-dividing sampling circuit is to obtain the required voltage value by connecting two or more resistors in series and dividing the voltage at both ends of the resistor. Specifically, the voltage on the motor terminal is divided by the resistor voltage-dividing circuit to obtain a voltage signal suitable for processing by the first processor 2. As a preferred embodiment, the resistor voltage-dividing sampling circuit can be composed of high-precision resistors to ensure the accuracy and stability of the sampled voltage.

[0050] By adopting the above-mentioned resistor voltage-dividing sampling circuit, this embodiment can realize accurate sampling of the voltage on the motor terminal and provide reliable voltage information to the first processor 2, thereby effectively judging the running state of the motor. This design not only simplifies the structure of the voltage sampling module 7, but also improves the reliability and stability of the system. It can be seen that this embodiment provides an accurate and efficient voltage sampling method, which helps to improve the overall performance of the internal environment monitoring system of the explosion-proof motor junction box.

[0051] In practical applications, the voltage sampling module 7 can be implemented in a variety of ways, such as a resistor voltage-dividing sampling circuit, an operational amplifier sampling circuit, etc. The power processing module 9 can use a combination of a DC-DC converter and an AC-DC converter to achieve AC-DC conversion of electric energy and high-low voltage conversion to meet the power requirements of different sensors and batteries 8.

[0052] The battery 8 can be selected from different types of rechargeable batteries, such as lithium-ion batteries, nickel-metal hydride batteries, etc., and the appropriate battery type and capacity can be selected according to actual needs.

[0053] When the motor is in operation, the first processor 2 controls the power processing module 9 to draw power from the motor terminals. After the power processing module 9 performs AC-DC conversion and high-low voltage conversion on the obtained electrical energy, it supplies power to the environmental monitoring sensor 1, the first processor 2 and the first carrier module 3, and charges the battery 8 at the same time.

[0054] When the motor is in a stopped state, the electric energy of the battery 8 is converted into power by the power processing module 9 to power the environment monitoring sensor 1, the first processor 2 and the first carrier module 3 to maintain continuous operation of environment monitoring and data transmission.

[0055] It can be seen that this embodiment realizes the function of automatically switching the power supply according to the operating status of the motor by adding a voltage sampling module 7, a battery 8 and a power processing module 9 in the junction box. No additional power supply is required, which solves the problem of additional wiring required in the traditional solution, improves the reliability and practicality of the system, and effectively avoids environmental monitoring interruptions caused by power interruptions, thereby ensuring the continuous safe operation of the explosion-proof motor.

[0056] See also Figure 2 This embodiment also provides a method for monitoring safety hazards of explosion-proof motor junction boxes, which includes but is not limited to the following steps:

[0057] Step S1, obtaining environmental information inside the junction box 10, such as temperature and humidity;

[0058] Step S2, converting the acquired environmental information into a digital signal, and modulating the digital signal into a carrier signal by a carrier module, and then coupling it to the power cable 20 of the motor;

[0059] Step S3, transmitting the carrier signal to the contactor outlet of the switch cabinet 30 in a power carrier mode through the power cable 20;

[0060] Step S4: at the switch cabinet 30 end, the received carrier signal is converted into a digital signal by another carrier module and sent to the processor;

[0061] Step S5: The processor processes the received digital signal through an algorithm to obtain environmental status data inside the junction box 10;

[0062] Step S6, sending the environmental status data to the monitoring terminal 40 via wireless transmission;

[0063] Step S7: The monitoring terminal 40 analyzes and processes the environmental status data to determine whether there is a potential safety hazard in the junction box 10, and notifies the user of the determination result by display and / or voice.

[0064] Furthermore, in the process of executing the above potential safety hazard monitoring method, the following steps are also included:

[0065] A reasonable temperature range and a reasonable humidity range are preset in the monitoring terminal 40; the measured temperature is compared with the preset reasonable temperature range to determine whether the temperature in the junction box 10 is normal; the measured humidity is compared with the preset reasonable humidity range to determine whether the humidity in the junction box 10 is normal; when at least one of the temperature or humidity in the junction box 10 is abnormal, it is determined that the junction box 10 has a safety hazard.

[0066] Furthermore, in the process of executing the above potential safety hazard monitoring method, the following steps are also included:

[0067] When the motor is in running state, the battery 8 is charged and the environmental monitoring sensor 1, the first processor 2 and the first carrier module 3 are powered through the power cable 20 of the motor; when the motor is in stopping state, the battery 8 powers the environmental monitoring sensor 1, the first processor 2 and the first carrier module 3.

[0068] This embodiment provides different power supply schemes for the running and stopping states of the motor, thereby ensuring the continuous operation of the environmental monitoring system, solving the problem of possible interruption of environmental monitoring in the prior art, and improving the reliability of the system.

[0069] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. An environment monitoring system inside an explosion-proof motor junction box, characterized in that: It includes an environmental monitoring sensor, a first processor and a first carrier module located in a junction box, a second carrier module, a second processor and a wireless communication module located in a switch cabinet, and a monitoring terminal; The environmental monitoring sensor is used to measure environmental information in the junction box and send the measured environmental information to the first processor; The first processor is used to convert the environmental information into a digital signal and send it to the first carrier module, and the first carrier module modulates the digital signal into a carrier signal and couples it to the power cable of the motor; The second carrier module is used to receive a carrier signal from the power cable, demodulate the carrier signal into a digital signal, and send it to the second processor; The second processor is used to process the received digital signal to obtain environmental status data, and send the environmental status data to the monitoring terminal in a wireless transmission manner through the wireless communication module; The monitoring terminal is used to determine whether there is a potential safety hazard in the junction box after processing and analyzing the environmental condition data, and inform the user through sound and / or display.

2. The explosion-proof motor junction box internal environment monitoring system according to claim 1 is characterized in that: It also includes a voltage sampling module, a battery and a power processing module located in the junction box, wherein the voltage sampling module is connected to the motor terminal and is used to sample the voltage on the motor terminal and send the sampled voltage information to the first processor, wherein the first processor calculates the sampled voltage value and determines the current state of the motor; When the motor is in operation, the first processor controls the power processing module to obtain power from the motor terminal, and the power processing module performs AC-DC conversion and voltage high-low conversion on the obtained electric energy, and then supplies power to the environment monitoring sensor, the first processor and the first carrier module; When the motor is in a stopped state, the electric energy of the battery is converted into voltage by the power processing module to power the environment monitoring sensor, the first processor and the first carrier module to maintain continuous operation of environment monitoring and data transmission.

3. The internal environment monitoring system of the explosion-proof motor junction box according to claim 2 is characterized in that: The battery is a rechargeable battery. When the motor is in operation, the power processing module performs AC-DC conversion and voltage high-low conversion on the acquired electric energy and then charges the battery.

4. The internal environment monitoring system of the explosion-proof motor junction box according to claim 2 is characterized in that: The voltage sampling module is a resistor voltage division sampling circuit.

5. The explosion-proof motor junction box internal environment monitoring system according to claim 1, characterized in that: The environment monitoring sensor includes a temperature measurement sensor and a humidity measurement sensor. The temperature measurement sensor is used to measure the temperature in the junction box, and the humidity measurement sensor is used to measure the humidity in the junction box.

6. A method for monitoring safety hazards of explosion-proof motor junction boxes, characterized in that: The following steps are involved: Obtain environmental information inside the explosion-proof motor junction box; The environmental information is converted into a digital signal, the digital signal is modulated into a carrier signal by a first carrier module, and then coupled to a power cable of the motor; Transmitting the carrier signal to the contactor outlet of the switch cabinet via a power cable in a power carrier mode; The received carrier signal is converted into a digital signal by the second carrier module and sent to the processor, and the processor processes the received digital signal to obtain the environmental status data in the explosion-proof motor junction box; Send environmental status data to the monitoring terminal by wireless transmission; The monitoring terminal analyzes and processes the environmental status data to determine whether there is a potential safety hazard in the explosion-proof motor junction box, and notifies the user of the determination result by display and / or voice.

7. The method for monitoring safety hazards of explosion-proof motor junction boxes according to claim 6, characterized in that: The potential safety hazard monitoring method further comprises the following steps: Preset a reasonable temperature range and a reasonable humidity range in the monitoring terminal; compare the measured temperature with the preset reasonable temperature range to determine whether the temperature in the junction box is normal; compare the measured humidity with the preset reasonable humidity range to determine whether the humidity in the junction box is normal; When at least one of the temperature or the humidity in the junction box is abnormal, it is determined that there is a potential safety hazard in the junction box.

8. The method for monitoring safety hazards of explosion-proof motor junction boxes according to claim 6, characterized in that: The acquired environmental information includes the temperature and humidity in the junction box.

9. The method for monitoring safety hazards of explosion-proof motor junction boxes according to claim 6, characterized in that: The following steps are also included: When the motor is in operation, the battery is charged and the environment monitoring sensor, the first processor and the first carrier module are powered through the power cable of the motor; When the motor is in a stopped state, the battery supplies power to the environment monitoring sensor, the first processor and the first carrier module.

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