A sensor intelligent upgrading and reconstruction system and method

Abstract

The embodiment of the application provides a sensor intelligent upgrading and reconstruction system and method, the system comprises a sending module and a control cabinet, one end of the sending module is connected with a sensor, and the other end of the sending module is connected with the control cabinet; the sending module is used for collecting an analog current signal output by the sensor, converting the analog current signal into a digital signal, analyzing sensor data according to the digital signal to obtain a sensor data analysis result and determine a sensor operation state, and converting the digital signal into an analog signal and transmitting the analog signal and the analog current signal to the control cabinet; the control cabinet is used for demodulating and processing the analog current signal and obtaining an output analysis result; the analog current signal of the sensor can be collected in real time by the sending module, and is rapidly converted into a digital signal for processing, so that real-time analysis and on-site diagnosis of sensor data and sensor operation state monitoring are realized, and additional communication cables do not need to be laid, thereby reducing operation cost and maintenance workload.

Description

Technical Field

[0001] This invention relates to the field of sensor technology, and in particular to a sensor intelligent upgrade and transformation system and method. Background Technology

[0002] With the development of chip and communication technologies, some industrial sites are choosing to use "ordinary sensors + remote input / output modules + communication cables" to complete the measurement, sampling, and transmission of physical quantities. This technology uses digital electrical signals as the transmission carrier of physical quantities and has the characteristics of large data capacity, rich transmission information, and few on-site wiring. However, the sensors in business sites such as hydropower stations, photovoltaic power stations, and energy storage power stations are mostly ordinary sensors. If the "ordinary sensors + remote input / output modules + communication cables" approach is used for technical transformation, a large number of remote input / output modules will be required, and additional communication cables will need to be laid, which will increase the cost of on-site technical transformation and the workload of subsequent operation and maintenance. Summary of the Invention

[0003] In view of the above problems, embodiments of the present invention are proposed to provide a sensor intelligent upgrade and transformation system and method that overcomes or at least partially solves the above problems.

[0004] To address the aforementioned issues, this invention discloses a sensor intelligent upgrade and transformation system. The system includes a transmitting module and a control cabinet. One end of the transmitting module is connected to the sensor, and the other end of the transmitting module is connected to the control cabinet.

[0005] The transmitting module is used to collect the analog current signal output by the sensor, convert the analog current signal into a digital signal, analyze the sensing data based on the digital signal to obtain the sensing data analysis result, and determine the sensor operating status. The sensor operating status and the sensing data analysis result are converted into analog signals, and the analog current signal, the sensor operating status in analog signal form, and the sensor data analysis result are sent to the control cabinet through the channel corresponding to the sensor.

[0006] The control cabinet is used to analyze the analog current signal, the operating status of the sensor in the form of the analog signal, and the sensor data analysis results to obtain analysis results, and output the analysis results.

[0007] Optionally, the transmitting module further includes an analog-to-digital converter, an analog signal delay circuit, and a first analog signal isolation distributor, one end of which is connected to the sensor, and the other end of which is connected to the analog-to-digital converter and the analog signal delay circuit, respectively.

[0008] The first analog signal isolation distributor is used to acquire the analog current signal and send the analog current signal to the analog-to-digital converter and the analog signal delay circuit respectively;

[0009] The analog-to-digital converter is used to perform analog-to-digital conversion on the analog current signal to obtain the digital signal;

[0010] The analog signal delay circuit is used to obtain the delay duration and send the analog current signal to the control cabinet according to the delay duration.

[0011] Optionally, the analog signal delay circuit includes one of a capacitor-inductor delay line, an optical fiber delay line, and an analog phase shifter.

[0012] Optionally, the transmitting module further includes a microcontroller connected to the analog-to-digital converter. The microcontroller is used to acquire the digital signal transmitted by the analog-to-digital converter and query the operating status of the sensor according to the digital signal in a preset mapping relationship. The preset mapping relationship includes multiple mapping relationships between digital signals and operating status.

[0013] Optionally, the control cabinet includes a receiving module, a second analog signal isolation distributor, and a controller. The second analog signal isolation distributor is connected to the receiving module and the controller, respectively, and the receiving module is connected to the controller.

[0014] The second analog signal isolation distributor is used to receive the analog current signal and the sensor's operating status and sensor data analysis results in analog signal form sent by the transmitting module, send the analog current signal to the controller, and send the sensor's operating status and sensor data analysis results in analog signal form to the receiving module;

[0015] The receiving module is used to convert the operating status of the sensor in analog signal form and the sensor data analysis results into the operating status of the sensor in digital signal form and the sensor data analysis results, and send the operating status of the sensor in digital signal form and the sensor data analysis results to the controller;

[0016] The controller is used to perform similar feature matching based on the operating status of the sensor in digital signal form, the sensor data analysis results, and the analog current signal to obtain a digital signal offset, perform frequency domain calculation based on the digital signal offset to obtain a high-frequency signal value, and analyze the high-frequency signal value to obtain an analysis result.

[0017] Optionally, the receiving module includes an analog-to-digital sampler, which is used to collect the operating status of the sensor in analog signal form and the sensor data analysis results, and convert the operating status of the sensor in analog signal form into the operating status of the sensor in digital signal form and the sensor data analysis results.

[0018] Optionally, the analog-to-digital sampler is further configured to acquire encoding information, encode the packaged data packet according to the encoding information to obtain an encoded data packet, and send the encoded data packet to the controller.

[0019] Optionally, the encoding information includes at least one of error detection and correction codes and binary codes.

[0020] Optionally, the analog-to-digital sampler is further configured to package the operating status of the sensor in digital signal form and the sensor data analysis results according to a preset protocol, and send the packaged data packet to the controller;

[0021] The controller is used to parse the packaged data packet according to the preset protocol to obtain the operating status of the sensor in digital signal form and the sensor data analysis results.

[0022] Optionally, the receiving module further includes a channel control and encoding module, which is used to receive the control signal from the controller and control the target channel of the analog-to-digital sampler to switch on and off according to the controller signal.

[0023] Optionally, the system further includes a power module connected to the transmitting module, the power module being used to supply power to the transmitting module.

[0024] Optionally, the control cabinet is also connected to a computer monitoring system, which sends the analysis results to the computer monitoring system. The computer monitoring system issues a reminder when the analysis results indicate that the sensor is operating abnormally.

[0025] Optionally, the computer monitoring system is further configured to determine the abnormality level of the sensor's operating status when the sensor's operating status is abnormal, and issue a reminder message based on the abnormality level of the sensor's operating status.

[0026] This invention also discloses a method for intelligent upgrading and transformation of sensors, the method comprising:

[0027] The analog current signal output by the sensor is collected, the analog current signal is converted into a digital signal, and the sensor data is analyzed based on the digital signal to obtain the sensor data analysis result and determine the sensor operating status.

[0028] The sensor's operating status and the sensor data analysis results are converted into analog signals, and the analog current signal, the sensor's operating status in analog signal form, and the sensor data analysis results are sent to the control cabinet. The control cabinet then analyzes the analog current signal, the sensor's operating status in analog signal form, and the sensor data analysis results to obtain analysis results, and outputs the analysis results.

[0029] Optionally, determining the sensor's operating state based on the digital signal includes:

[0030] The operating status of the sensor is queried in a preset mapping relationship based on the digital signal. The preset mapping relationship includes multiple mapping relationships between digital signals and operating status.

[0031] The embodiments of the present invention have the following advantages:

[0032] This invention discloses a sensor intelligent upgrade and transformation system. The system can acquire analog current signals output by sensors via a transmitting module, convert these signals into digital signals, analyze the sensor data and sensor operating status based on the digital signals, and then convert the digital signals back into analog signals, transmitting them along with the analog current signals to a control cabinet. The control cabinet demodulates and processes the analog current signals to obtain the output analysis results. This invention can acquire analog current signals from sensors in real time via the transmitting module and quickly convert them into digital signals for processing, thereby achieving real-time analysis and on-site diagnosis of sensor data, as well as monitoring of sensor operating status. It eliminates the need for additional communication cables, reducing operating costs and maintenance workload. Attached Figure Description

[0033] Figure 1 This is a structural block diagram of a sensor intelligent upgrade and transformation system provided in an embodiment of the present invention.

[0034] Figure 2 This is a structural block diagram of a sending module provided in an embodiment of the present invention;

[0035] Figure 3 This is a structural block diagram of a control cabinet provided in an embodiment of the present invention;

[0036] Figure 4 This is a structural block diagram of a receiving module provided in an embodiment of the present invention;

[0037] Figure 5 This is a structural block diagram of another intelligent sensor upgrade and transformation system provided in an embodiment of the present invention;

[0038] Figure 6This is a flowchart of the steps of a sensor intelligent upgrade and transformation method provided in an embodiment of the present invention. Detailed Implementation

[0039] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0040] In clean energy power stations such as hydropower stations, photovoltaic power stations, and energy storage power stations, physical quantities such as temperature, pressure, flow rate, and displacement are generally converted into electrical signals for transmission. The transmission process can be divided into sensing transmission technology and communication transmission technology according to the signal type. The characteristics of each transmission technology are as follows: (1) Sensing transmission technology: This technology usually uses industrial cables to transmit analog electrical signals (4-20mA current signal or 0-5V voltage signal) output by electrical sensors. Since current signals have the characteristics of high safety, long transmission distance and strong anti-interference, 4-20mA analog current is commonly used as the standard transmission signal for this transmission technology in industrial sites. (2) Communication transmission technology: With the development of chip and communication technology, some industrial sites choose to use "intelligent sensor + communication cable" or "ordinary sensor + remote input / output module + communication cable" to complete the measurement, sampling and transmission of physical quantities. This technology uses digital electrical signals as the transmission carrier of physical quantities and has the characteristics of large data capacity, rich transmission information and few on-site wiring.

[0041] In comparison, communication transmission technology has more obvious technological advantages and is an important technological trend for future field sensor data transmission. However, the sensors in operational sites such as hydropower stations, photovoltaic power stations, and energy storage power stations are mostly ordinary sensors. If the technology is upgraded using the method of "ordinary sensors + remote input / output modules + communication cables", a large number of remote input / output modules will be required, and additional communication cables will need to be laid, increasing the cost of field technology upgrades and the workload of subsequent operation and maintenance.

[0042] One of the core concepts of this invention is that the analog current signal output by the sensor can be acquired by the transmitting module, converted into a digital signal, and the sensor data analysis results and sensor operating status can be obtained based on the digital signal analysis. After the digital signal is converted back into an analog signal, it is transmitted to the control cabinet along with the analog current signal. The control cabinet is used to demodulate and process the analog current signal and obtain the output analysis result. This invention can acquire the analog current signal of the sensor in real time by the transmitting module and quickly convert it into a digital signal for processing, thereby realizing real-time analysis and on-site diagnosis of sensor data, as well as monitoring of sensor operating status. It does not require additional communication cables, reducing operating costs and maintenance workload. Through continuous monitoring and analysis of the sensor operating status, the system can issue timely warnings when the sensor is abnormal or about to fail, which helps preventive maintenance and reduces production interruptions.

[0043] Reference Figure 1 The diagram shows a structural block diagram of a sensor intelligent upgrade and transformation system 10 provided by an embodiment of the present invention. The system may include a transmitting module 101 and a control cabinet 102. One end of the transmitting module 101 is connected to the sensor 20, and the other end of the transmitting module 101 is connected to the control cabinet 102.

[0044] The transmitting module is used to acquire the analog current signal output by the sensor, convert the analog current signal into a digital signal, analyze the sensor data based on the digital signal to obtain the sensor data analysis result, and determine the sensor's operating status. The sensor's operating status and sensor data analysis result are converted into analog signals, and the analog current signal, the sensor's operating status in analog signal form, and the transmitted sensor data analysis result are sent to the control cabinet through the sensor's corresponding channel.

[0045] In this embodiment of the invention, sensor 20 can be a flow sensor, temperature sensor, or humidity sensor in a hydropower station. The sensor can output a 4-20mA analog current signal, and the output interface can be two-wire, three-wire, or four-wire. The transmitting module 101 can collect the analog current signal output by the sensor, then convert the analog current signal into a digital signal, and then analyze and diagnose the digital signal to determine the sensor's operating status and the sensor data analysis results transmitted by the sensor. After obtaining the sensor's operating status and the sensor data analysis results in digital signal form, the sensor's operating status and the sensor data analysis results in digital signal form can be converted into the sensor's operating status and sensor data analysis results in analog signal form, and then the analog current signal, the sensor's operating status and sensor data analysis results in analog signal form can be sent to the control cabinet 102.

[0046] It should be noted that different sensors can transmit data through different transmission channels. For example, a flow sensor can be set to channel 1 for transmission, a temperature sensor to channel 2 for transmission, and a pressure sensor to channel 3 for transmission. If the transmitting module collects data from a temperature sensor, channel 2 can be used to transmit analog current signals, sensor operating status in analog signal form, and sensor data analysis results.

[0047] Sensor data analysis results refer to the results obtained by analyzing sensor data collected by sensors (which can be parameters such as temperature, current, flow rate, etc., and the specific type is not limited here), including feature extraction, anomaly detection, etc.

[0048] The control cabinet is used to analyze the operating status of analog current signals and sensors in analog signal form, as well as the sensor data analysis results, to obtain and output the analysis results.

[0049] In this embodiment of the invention, the control cabinet 102 can receive the analog current signal of the sensor and the sensor's operating status and sensor data analysis results in analog signal form sent by the sending module 101. Then, it can parse the data to obtain the analysis results and output them. The analysis results may include whether the sensor's operating status is normal and whether the sensor data analysis results are normal. The user can process the sensor according to the analysis results. By converting the sensor's operating status into an analog signal and sending it to the control cabinet, the system can provide real-time status feedback, helping operators or automation systems to quickly understand the current status of the sensor.

[0050] This invention discloses a sensor intelligent upgrade and transformation system. It can acquire analog current signals output by sensors via a transmitting module, convert these signals into digital signals, analyze the sensor data and sensor operating status based on the digital signals, and then convert the digital signals back into analog signals, transmitting them along with the analog current signals to a control cabinet. The control cabinet demodulates and processes the analog current signals to obtain the output analysis results. This invention can acquire analog current signals from sensors in real time via the transmitting module and quickly convert them into digital signals for processing, thereby achieving real-time analysis and on-site diagnosis of sensor data, as well as monitoring of sensor operating status. It eliminates the need for additional communication cables, reducing operating costs and maintenance workload. Through continuous monitoring and analysis of sensor operating status, the system can issue timely warnings when sensors malfunction or are about to fail, facilitating preventative maintenance and reducing production interruptions.

[0051] In one embodiment of the present invention, the transmitting module further includes an analog-to-digital converter, an analog signal delay circuit, and a first analog signal isolation distributor. One end of the first analog signal isolation distributor is connected to the sensor, and the other end of the first analog signal isolation distributor is connected to the analog-to-digital converter and the analog signal delay circuit, respectively.

[0052] The first analog signal isolation distributor is used to collect analog current signals and send the analog current signals to the analog-to-digital converter and the analog signal delay circuit respectively.

[0053] Analog-to-digital converters are used to convert analog current signals into digital signals.

[0054] The analog signal delay circuit is used to obtain the delay duration and send the analog current signal to the control cabinet according to the delay duration.

[0055] In embodiments of the present invention, such as Figure 2 The diagram shows a structural block diagram of a transmitting module 101 provided in an embodiment of the present invention. The transmitting module 101 may include an analog-to-digital converter 1012, a first analog signal isolation distributor 1011, and an analog signal delay circuit 1013 connected together.

[0056] An analog signal isolation distributor is an electronic device used to distribute the output of an analog signal source to multiple output channels while maintaining signal isolation and integrity. This device is very useful in industrial automation, process control, instrumentation, and communication systems because it can prevent signals from being interfered with by electrical noise, protect the signal source from the influence of external circuits, and enable multi-point transmission of signals.

[0057] The first analog signal isolation distributor 1011 can collect the analog current signal output by the sensor, and then send the analog current signal to the analog-to-digital converter 1012 and the analog signal delay circuit 1013 respectively.

[0058] An ADC (Analog-to-Digital Converter) is an electronic device used to convert continuously changing analog signals into discrete digital signals. This conversion is a key step in digital signal processing, data acquisition, and control systems because it allows analog signals to be processed and analyzed by digital computers or microprocessors. The analog-to-digital converter 1012 of this invention is used to sample analog current signals into digital signals composed of 1s and 0s, with a sampling precision of 8 bits or 12 bits.

[0059] The analog signal delay circuit 1013 is an electronic circuit used to delay the input analog signal for a certain period of time before outputting it. This circuit is very useful in fields such as communication systems, audio processing, video processing, and radar systems because it can be used to synchronize signals, eliminate echoes, and adjust the phase of signals.

[0060] In one embodiment of the present invention, the analog signal delay circuit includes one of a capacitor-inductor delay line, an optical fiber delay line, and an analog phase shifter.

[0061] In this embodiment of the invention, the analog signal delay circuit can typically achieve signal delay using the following techniques:

[0062] Transmission line delay line: A transmission line of a specific length (such as a coaxial cable) used to physically delay a signal. Since the speed at which a signal propagates through a transmission line is finite, the desired delay can be achieved by selecting an appropriate length of transmission line.

[0063] Capacitor-inductor (LC) delay lines: These use a combination of inductors and capacitors to create a filter network that delays signals as they pass through it. This type of delay line can be designed with specific frequency responses and delay times.

[0064] Analog phase shifters: These achieve delay by changing the phase of a signal. In some applications, variable capacitors or variable inductors can be used to adjust the phase of the signal, thereby indirectly adjusting the signal delay time.

[0065] Digital delay line: Although the name includes "digital", digital delay lines can also be used to delay analog signals. In this method, the analog signal is first converted into a digital signal, then delayed by a digital delay line (such as a shift register), and finally converted back into an analog signal.

[0066] Fiber optic delay lines: In some high-speed or long-distance applications, optical fibers can be used to delay analog signals. The signal is first converted into an optical signal, transmitted through the optical fiber, and then converted back into an electrical signal.

[0067] The specific type used is not limited here. This invention can realize the synchronous transmission of analog current signals and digital signals through analog signal delay circuit, which helps to improve the accuracy and consistency of data analysis.

[0068] In one embodiment of the present invention, the transmitting module further includes a microcontroller connected to an analog-to-digital converter. The microcontroller is used to acquire the digital signal transmitted by the analog-to-digital converter and query the operating status of the sensor according to the digital signal in a preset mapping relationship. The preset mapping relationship includes multiple mapping relationships between digital signals and operating status.

[0069] In embodiments of the present invention, such as Figure 2 The transmitting module 101 may also include a microcontroller 1014, which is connected to the analog-to-digital converter 1012. The microcontroller 1014 can acquire the digital signal sent by the analog-to-digital converter 1012 and then query the operating status of the sensor corresponding to the digital signal according to the preset mapping relationship stored in the pre-stored database. For example, digital signal 1 may correspond to the sensor working normally, and digital signal 0 may indicate that the sensor is overheating or malfunctioning.

[0070] In one embodiment of the present invention, the transmitting module further includes a digital-to-analog converter, which is connected to the microcontroller and the control cabinet respectively. The digital-to-analog converter is used to convert the operating status of the sensor in the form of a digital signal sent by the microcontroller into the operating status of the sensor in the form of an analog signal.

[0071] It should be noted that the specific mapping relationship between digital signals and operating status can be set according to user needs, and is not limited here.

[0072] In embodiments of the present invention, such as Figure 2The transmitting module 101 may also include a digital-to-analog converter 1015, which is connected to the microcontroller 1014 and the control cabinet 102 respectively. The digital-to-analog converter can convert the sensor's operating status and sensor data analysis results in the form of digital signals sent by the microcontroller 1014 into the sensor's operating status and sensor data analysis results in the form of analog signals. The DAC receives the digital signals sent by the microcontroller and converts them into corresponding analog current signals. The conversion accuracy depends on the resolution of the DAC. For example, an 8-bit, 12-bit, or 16-bit DAC can convert digital signals into 256, 4096, or 65536 different analog levels.

[0073] In one embodiment of the present invention, the control cabinet includes a receiving module, a second analog signal isolation distributor, and a controller. The second analog signal isolation distributor is connected to the receiving module and the controller, respectively. The receiving module is connected to the controller.

[0074] The second analog signal isolation distributor is used to receive the analog current signal and the sensor operating status and sensor data analysis results in analog signal form sent by the transmitting module, send the analog current signal to the controller, and send the sensor operating status and sensor data analysis results in analog signal form to the receiving module.

[0075] The receiving module is used to convert the sensor's operating status and sensor data analysis results in analog signal form into the sensor's operating status and sensor data analysis results in digital signal form, and send the sensor's operating status and sensor data analysis results in digital signal form to the controller;

[0076] The controller is used to perform similar feature matching based on the operating status of the sensor in digital signal form, the sensor data analysis results, and the analog current signal to obtain the digital signal offset. Based on the digital signal offset, the controller performs frequency domain calculation to obtain the high-frequency signal value and analyzes the high-frequency signal value to obtain the analysis result.

[0077] In embodiments of the present invention, such as Figure 3 The diagram shows a structural block diagram of a control cabinet 102 provided in an embodiment of the present invention. The control cabinet 102 may include a receiving module 1022, a controller 1023, and a second analog signal isolation distributor. The second analog signal isolation distributor 1021 can receive the analog current signal and the operating status and sensor data analysis results in analog signal form sent by the sending module 101, and then send the analog current signal to the controller 1023, and send the operating status and sensor data analysis results in analog signal form to the receiving module 1022.

[0078] The receiving module 1022 can convert the sensor's operating status and sensor data analysis results in analog signal form into the sensor's operating status and sensor data analysis results in digital signal form, and send the sensor's operating status and sensor data analysis results in digital signal form to the controller 1023.

[0079] After receiving the operating status and sensor data analysis results of the analog current signal and digital signal form of the sensor, the controller 1023 can perform similar feature matching based on the operating status and sensor data analysis results of the digital signal form of the sensor and the analog current signal to obtain the digital signal offset. The controller 1023 uses Fast Fourier Transform (FFT) or other frequency domain analysis techniques to convert the digital signal to the frequency domain. In the frequency domain, the controller 1023 can identify and extract high-frequency signal values, perform frequency domain calculations based on the digital signal offset to obtain the high-frequency signal values, and analyze the high-frequency signal values ​​to obtain the analysis results.

[0080] It should be noted that the controller is a programmable logic controller (PLC), which is commonly used in industrial control systems. A PLC is a digital computer specifically designed for industrial environments and used for automated control processes. PLCs can perform tasks such as logic operations, sequential control, timing, counting, and arithmetic operations.

[0081] In one embodiment of the present invention, the receiving module includes an analog-to-digital sampler, which is used to collect the operating status and sensor data analysis results of the sensor in analog signal form, and convert the operating status and sensor data analysis results of the sensor in analog signal form into the operating status and sensor data analysis results of the sensor in digital signal form.

[0082] In embodiments of the present invention, such as Figure 4 The diagram shows a structural block diagram of a receiving module 1022 provided in an embodiment of the present invention. The receiving module 1022 may include an analog-to-digital sampler 10221, which is used to collect the operating status and sensor data analysis results of the sensor in analog signal form, and convert the operating status and sensor data analysis results of the sensor in analog signal form into the operating status of the sensor in digital signal form.

[0083] In one embodiment of the present invention, the analog-to-digital sampler is further configured to package the operating status of the sensor in digital signal form according to a preset protocol, and send the packaged data packet to the controller; the controller is configured to parse the packaged data packet according to the preset protocol to obtain the operating status of the sensor in digital signal form.

[0084] In this embodiment of the invention, the analog-to-digital sampler 10221 can package the raw data into a specific format according to a preset protocol, including adding header information (such as source address, destination address, data type, sequence number, etc.) and trailer information (such as checksum, end marker, etc.), and then send the packaged data packet to the controller 1023. The controller 1023 can parse the header and trailer information of the data packet according to the preset protocol, extract the raw data, and parse the header information to determine the source, destination, type and other relevant parameters of the data.

[0085] In one embodiment of the present invention, the analog-to-digital sampler is further used to acquire encoding information, encode the packaged data packet according to the encoding information to obtain an encoded data packet, and send the encoded data packet to the controller.

[0086] The encoded information may include at least one of error detection and correction codes and binary codes.

[0087] In this embodiment of the invention, the analog-to-digital sampler can also encode the packaged data to ensure its integrity and reliability during transmission. This can include using specific encoding schemes (such as ASCII, UTF-8, binary encoding, etc.) and error detection and correction codes (such as CRC, Hamming codes, etc.).

[0088] The controller 1023 can decode the received data, remove the encoding and error detection information added during transmission, and verify the integrity of the data, such as by checking the checksum or using error correction codes to fix possible transmission errors.

[0089] In one embodiment of the present invention, the receiving module further includes a channel control and encoding module, which is used to receive control signals from the controller and control the target channel of the analog-to-digital sampler to switch on and off according to the controller signals.

[0090] In embodiments of the present invention, such as Figure 4 The receiving module 102 may further include a channel control and encoding module 10222. The analog-to-digital sampler 10221 may include multiple data transmission channels. The channel control and encoding module 10222 can receive control signals from the controller 1023 and control the switching of the target channel of the analog-to-digital sampler 10221 according to the controller signals. For example, 0000, 0100, 0000 indicates that the target channel 6 is in a connected state, and other channels are in a disconnected state. At this time, only the data of channel 6 is collected. The present invention can enable or disable specific data transmission channels as needed to optimize the data acquisition process, reduce power consumption, or avoid unnecessary signal interference.

[0091] For example, channel 1 is a data transmission channel for a flow sensor, channel 2 is a data transmission channel for a current sensor, and channel 3 is a data transmission channel for a temperature sensor. When there are 10 data transmission channels, and it is necessary to detect the sensor data output by the temperature sensor, the controller can generate a control signal of 0010000000 to the channel control and encoding module. The channel control and encoding module can open channel 3 and close other channels according to the control signal.

[0092] In one embodiment of the present invention, the system further includes a power supply module connected to the transmitting module, which supplies power to the transmitting module.

[0093] In embodiments of the present invention, such as Figure 5 The diagram shows a structural block diagram of another sensor monitoring system provided in an embodiment of the present invention. The system also includes a power supply module 103, which is connected to the transmission module 101. The power supply module 103 is used to supply power to the transmission module 101. The power supply module can be a 24V standard DC power supply to supply power to the transmission module 101.

[0094] In one embodiment of the present invention, the control cabinet is also connected to a computer monitoring system. The control cabinet is used to send the analysis results to the computer monitoring system, and the computer monitoring system is used to issue a reminder message when the analysis results show that the sensor is malfunctioning.

[0095] In embodiments of the present invention, such as Figure 5 The monitoring system is also connected to the computer monitoring system 30. The controller 102 in the control cabinet 10 can send the analysis results to the computer monitoring system. The computer monitoring system 30 can issue an alert when the analysis results indicate that the sensor is malfunctioning. After receiving the alert, operators or maintenance teams can take corresponding measures, such as checking the sensor, adjusting system parameters, performing maintenance, or replacing faulty components. This invention can issue timely alerts when an anomaly is detected, thereby improving the safety and reliability of the system.

[0096] The timeliness and accuracy of alerts are crucial for quickly responding to potential problems, reducing downtime, and improving system reliability.

[0097] In one embodiment of the present invention, the computer monitoring system is further configured to determine the abnormality level of the sensor's operating state when the sensor's operating state is abnormal, and issue a reminder message based on the abnormality level of the sensor's operating state.

[0098] In this embodiment of the invention, the level of the alert information can be determined based on the abnormality level of the sensor's operating status. Specifically, assuming there is a temperature sensor on an industrial production line, the abnormality level of the temperature sensor can be divided into low, medium, and high levels. Based on the low, medium, and high levels of the temperature sensor, low-level alert information, medium-level alert information, and high-level alert information can be issued respectively. This invention can intelligently take corresponding measures according to the alarm level to ensure that the fault is dealt with in a timely manner before it becomes serious, thereby improving the safety and reliability of the system.

[0099] This invention discloses a sensor intelligent upgrade and transformation system. The system can acquire analog current signals output by sensors via a transmitting module, convert these signals into digital signals, analyze the sensor data and sensor operating status based on the digital signals, and then convert the digital signals back into analog signals, transmitting them along with the analog current signals to a control cabinet. The control cabinet demodulates and processes the analog current signals to obtain the output analysis results. This invention can acquire analog current signals from sensors in real time via the transmitting module and quickly convert them into digital signals for processing, thereby achieving real-time analysis and on-site diagnosis of sensor data, as well as monitoring of sensor operating status. It eliminates the need for additional communication cables, reducing operating costs and maintenance workload. The system can realize functions such as sensor status monitoring, sensor data preprocessing, and sensor data semantic transmission without altering the cabling architecture of the industrial control system, and features low cost, high reliability, and easy installation.

[0100] As the device embodiment is basically similar to the method embodiment, the description is relatively simple, and relevant parts can be found in the description of the method embodiment.

[0101] like Figure 6 The diagram illustrates a flowchart of a sensor intelligent upgrade and transformation method provided by an embodiment of the present invention. The method may include the following steps:

[0102] Step 401: Acquire the analog current signal output by the sensor and convert the analog current signal into a digital signal.

[0103] Step 402: Analyze the sensor data based on the digital signal to obtain the sensor data analysis results and determine the sensor operating status.

[0104] In one embodiment of the present invention, determining the sensor operating state based on digital signals includes: querying the sensor operating state in a preset mapping relationship based on the digital signals, wherein the preset mapping relationship includes multiple mapping relationships between digital signals and operating states.

[0105] In this embodiment of the invention, a digital signal can be acquired, and then the operating status of the sensor corresponding to the digital signal can be queried according to a pre-stored preset mapping relationship. For example, digital signal 1 may correspond to the sensor working normally, and digital signal 0 may indicate that the sensor is overheating or malfunctioning.

[0106] Step 403: Convert the sensor's operating status and sensor data analysis results into analog signals, and send the analog current signal and the analog signal form of the sensor's operating status and sensor data analysis results to the control cabinet, so that the control cabinet can parse the analog current signal and the analog signal form of the sensor's operating status and sensor data analysis results to obtain the parsing results and output the parsing results.

[0107] In this embodiment of the invention, the control cabinet can receive the analog current signal from the sensor, the sensor's operating status in analog signal form, and the sensor data analysis results. It then parses these signals to obtain the analysis results, which are then output. The analysis results can include whether the sensor's operating status is normal and whether the sensor data analysis results are normal. Users can then process the sensor accordingly based on the analysis results. By converting the sensor's operating status into an analog signal and sending it to the control cabinet, the system can provide real-time status feedback, helping operators or automated systems quickly understand the sensor's current condition and providing convenience for users.

[0108] This invention discloses a method for intelligent upgrading and transformation of sensors. The invention can acquire analog current signals output by sensors via a transmitting module, convert the analog current signals into digital signals, analyze the sensor data and sensor operating status based on the digital signals, and then convert the digital signals back into analog signals, transmitting them along with the analog current signals to the control cabinet. The control cabinet is used to demodulate and process the analog current signals and obtain the output analysis results. This invention can acquire analog current signals from sensors in real time via the transmitting module and quickly convert them into digital signals for processing, thereby realizing real-time analysis and on-site diagnosis of sensor data, as well as monitoring of sensor operating status. It eliminates the need for additional communication cables, reducing operating costs and maintenance workload. It can achieve functions such as sensor status monitoring, sensor data preprocessing, and sensor data semantic transmission without changing the cabling architecture of the industrial control system, and features low cost, high reliability, and easy installation.

[0109] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0110] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, apparatus, or computer program products. Therefore, embodiments of the present invention can take the form of entirely hardware embodiments, entirely software embodiments, or embodiments combining software and hardware aspects. Furthermore, embodiments of the present invention can take the form of computer program products implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0111] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, terminal devices (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing terminal device to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing terminal device, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0112] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing terminal device to operate in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0113] These computer program instructions can also be loaded onto a computer or other programmable data processing terminal equipment, causing a series of operational steps to be performed on the computer or other programmable terminal equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable terminal equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0114] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the embodiments of the present invention.

[0115] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0116] The present invention provides a detailed description of a sensor intelligent upgrade and transformation system and method. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A sensor intelligent upgrade and transformation system, characterized in that, The system includes a transmitting module and a control cabinet. One end of the transmitting module is connected to the sensor, and the other end of the transmitting module is connected to the control cabinet. The transmitting module is used to collect the analog current signal output by the sensor, convert the analog current signal into a digital signal, analyze the sensor data based on the digital signal to obtain the sensor data analysis result, and determine the sensor operating status. The sensor operating status and the sensor data analysis result are converted into analog signals, and the analog current signal, the sensor operating status in analog signal form, and the sensor data analysis result are sent to the control cabinet through the channel corresponding to the sensor. The control cabinet is used to analyze the analog current signal, the operating status of the sensor in the form of the analog signal, and the sensor data analysis results to obtain analysis results, and output the analysis results; The transmitting module further includes an analog-to-digital converter, an analog signal delay circuit, and a first analog signal isolation distributor. One end of the first analog signal isolation distributor is connected to the sensor, and the other end of the first analog signal isolation distributor is connected to the analog-to-digital converter and the analog signal delay circuit, respectively. The first analog signal isolation distributor is used to acquire the analog current signal and send the analog current signal to the analog-to-digital converter and the analog signal delay circuit respectively; The analog-to-digital converter is used to perform analog-to-digital conversion on the analog current signal to obtain the digital signal; The analog signal delay circuit is used to obtain the delay duration and send the analog current signal to the control cabinet according to the delay duration.

2. The system according to claim 1, characterized in that, The analog signal delay circuit includes one of the following: a capacitor-inductor delay line, an optical fiber delay line, and an analog phase shifter.

3. The system according to claim 1, characterized in that, The transmitting module further includes a microcontroller connected to the analog-to-digital converter. The microcontroller is used to acquire the digital signal transmitted by the analog-to-digital converter and query the operating status of the sensor according to the digital signal in a preset mapping relationship. The preset mapping relationship includes multiple mapping relationships between digital signals and operating status.

4. The system according to claim 3, characterized in that, The transmitting module further includes a digital-to-analog converter, which is connected to the microcontroller and the control cabinet respectively. The digital-to-analog converter is used to convert the operating status of the sensor and the sensor data analysis results in the form of digital signals sent by the microcontroller into the operating status of the sensor and the sensor data analysis results in the form of analog signals.

5. The system according to claim 1, characterized in that, The control cabinet includes a receiving module, a second analog signal isolation distributor, and a controller. The second analog signal isolation distributor is connected to the receiving module and the controller, respectively. The receiving module is connected to the controller. The second analog signal isolation distributor is used to receive the analog current signal and the sensor's operating status and sensor data analysis results in analog signal form sent by the transmitting module, send the analog current signal to the controller, and send the sensor's operating status and sensor data analysis results in analog signal form to the receiving module; The receiving module is used to convert the operating status of the sensor in analog signal form and the sensor data analysis results into the operating status of the sensor in digital signal form and the sensor data analysis results, and send the operating status of the sensor in digital signal form and the sensor data analysis results to the controller; The controller is used to perform similar feature matching based on the operating status of the sensor in digital signal form, the sensor data analysis results, and the analog current signal to obtain a digital signal offset, perform frequency domain calculation based on the digital signal offset to obtain a high-frequency signal value, and analyze the high-frequency signal value to obtain an analysis result.

6. The system according to claim 5, characterized in that, The receiving module includes an analog-to-digital sampler, which is used to collect the operating status of the sensor in analog signal form and the sensor data analysis results, and convert the operating status of the sensor in analog signal form into the operating status of the sensor in digital signal form and the sensor data analysis results.

7. The system according to claim 6, characterized in that, The analog-to-digital sampler is also used to package the operating status of the sensor in digital signal form and the sensor data analysis results according to a preset protocol, and send the packaged data packet to the controller; The controller is used to parse the packaged data packet according to the preset protocol to obtain the sensor's operating status and sensor data analysis results in the form of digital signals.

8. The system according to claim 7, characterized in that, The analog-to-digital sampler is also used to acquire encoding information, encode the packaged data packet according to the encoding information to obtain an encoded data packet, and send the encoded data packet to the controller.

9. The system according to claim 8, characterized in that, The encoded information includes at least one of error detection and correction codes and binary codes.

10. The system according to claim 7, characterized in that, The receiving module further includes a channel control and encoding module, which is used to receive the control signal from the controller and control the target channel of the analog-to-digital sampler to switch on and off according to the controller signal.

11. The system according to claim 1, characterized in that, The system also includes a power module connected to the transmitting module, which supplies power to the transmitting module.

12. The system according to claim 1, characterized in that, The control cabinet is also connected to a computer monitoring system. The control cabinet is used to send the analysis results to the computer monitoring system. The computer monitoring system is used to issue a reminder message when the analysis results show that the sensor is operating abnormally.

13. The system according to claim 12, characterized in that, The computer monitoring system is also used to determine the abnormality level of the sensor's operating status when the sensor's operating status is abnormal, and to issue a reminder message based on the abnormality level of the sensor's operating status.

14. A method for intelligent upgrading and transformation of sensors, characterized in that, The method includes: The analog current signal output by the sensor is acquired and converted into a digital signal. Based on the analysis of the digital signal, the sensor data analysis results are obtained, and the operating status of the sensor is determined. The sensor's operating status and the sensor data analysis results are converted into analog signals, and the analog current signal, the sensor's operating status in analog signal form, and the sensor data analysis results are sent to the control cabinet, so that the control cabinet can analyze the analog current signal, the sensor's operating status in analog signal form, and the sensor data analysis results to obtain analysis results, and output the analysis results. The step of acquiring the analog current signal output by the sensor and converting the analog current signal into a digital signal includes: acquiring the analog current signal through a first analog signal isolation distributor and converting the analog current signal into a digital signal; The analog current signal is converted to digital signal by analog-to-digital converter; The step of transmitting the analog current signal to the control cabinet includes: obtaining the delay duration through an analog signal delay circuit, and sending the analog current signal to the control cabinet according to the delay duration.

15. The method according to claim 14, characterized in that, Determining the sensor's operating status based on the digital signal includes: The operating status of the sensor is queried in a preset mapping relationship based on the digital signal. The preset mapping relationship includes multiple mapping relationships between digital signals and operating status.

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