Two-wire system flow protection switch

Abstract

The invention provides a two-wire system flow protection switch, and relates to the field of automatic flow control. The protection switch comprises a switch control instrument module, a connecting valve group, a medium buffer flow guide pipe, a drain outlet, a flow energy conversion module and a medium flow collection pipeline, a sensor and a logic execution module are embedded in the switch control instrument module; one end of the medium buffer flow guide pipe is connected to the medium flow collection pipeline through the flow energy conversion module, and the other end is connected to the connecting valve group; the medium flow is introduced into the switch control instrument module by the connecting valve group; the flow energy conversion module converts energy generated when the medium flows into electric energy to supply power to the switch control instrument module. The protection switch is provided with a multi-mode energy collection management module, and accurate measurement of flow is realized by utilizing the integrated ultra-low power consumption circuit intelligent control, a configuration type logic control module, a flow measurement auxiliary device and other related module combined collection technologies.

Description

Technical Field

[0001] The invention relates to the field of automatic flow control, and in particular to a two-wire flow protection switch. Background Art

[0002] In existing industrial automation systems, flow protection switches are one of the key components to ensure the safe operation of equipment. Traditional electronic flow meters mostly require an external power supply to drive sensors, processors and combined actuators, and the configuration method is not flexible, which not only increases the complexity and maintenance cost of the system, but also increases the incoordination between electronic control and mechanics, and there is hysteresis.

[0003] There are two types of flow switches on the market: electronic flow protection switches and mechanical flow protection switches.

[0004] Electronic flow switches are mostly realized by combining related electronic instruments and mechanical relays. This method has complex wiring, relatively inflexible installation, low overall instrument integration, relatively high cost, and inconvenient maintenance. It is difficult to meet the needs of modern industry for high efficiency, precision, and energy saving due to high power consumption, insufficient measurement accuracy, mechanical hysteresis or jamming, and low degree of intelligent integration.

[0005] Mechanical flow switches are unreliable. When checking flow switches, it is often found that when the given flow is lower than the set value, the flow switch does not work, and when it is hit with an object, it returns to normal, with a large dead zone; malfunctions. Users report that malfunctions have occurred many times when the flow in the pipeline fluctuates slightly; flow switch jams, drifts, ruptures, etc.; poor contact caused by contact oxidation, sparks, etc.; environmental influences, drift, reduced measurement accuracy, and increased maintenance and calibration workload. The product life cycle is short.

[0006] Therefore, it is of great significance to develop an intelligent, digitally displayed, energy collection and conversion, ultra-low power consumption, two-wire flow protection contactless switch. This intelligent flow control switch overcomes the shortcomings of mechanical switches and electronic flow switches and achieves perfect replacement. Summary of the invention

[0007] Purpose of the invention: In view of the above problems raised by the prior art, the present invention proposes a two-wire flow protection switch, which realizes accurate measurement and intelligent protection of flow by integrating a low-power control acquisition circuit module, a configurable control switch output module, an energy collection and conversion management module and a multi-combination flow measurement accessory, while reducing equipment power consumption, simplifying wiring, maintaining the two-wire working mode on site, and improving the overall performance and reliability of the system.

[0008] In order to achieve the above technical objectives, the technical solutions adopted by the present invention are as follows:

[0009] A two-wire flow protection switch comprises: a switch control instrument module, a connecting valve group, a medium buffer flow guide pipe, a sewage outlet, a flow energy conversion module, and a medium flow collection pipeline; wherein the switch control instrument module is electrically connected to the connecting valve group; the switch control instrument module is embedded with a sensor and a logic execution module; one end of the medium buffer flow guide pipe is connected to the medium flow collection pipeline through the flow energy conversion module, and the other end is connected to the connecting valve group; the connecting valve group introduces the medium flow in the medium buffer flow guide pipe into the switch control instrument module; the flow energy conversion module converts the energy generated when the medium flow flows into electrical energy to supply power to the switch control instrument module; the sewage outlet is arranged on one side of the connecting valve group; and the medium flow collection pipeline is fixed to the lower part of the connecting valve group.

[0010] In a further embodiment, the flow energy conversion module includes a micro-turbine generator or a piezoelectric material conversion controller.

[0011] In a further embodiment, the sensor includes at least one of a flow sensor, a temperature sensor, and a pressure sensor.

[0012] In a further embodiment, it is fixed to the medium flow collection pipeline by a pipeline clamp structure;

[0013] The pipeline clamp structure includes a fixed connecting plate fixed on the connecting valve group, and a fixed support frame is fixed on the bottom plane of the fixed connecting plate. The medium flow collection pipeline is abutted against the fixed support frame and fixed by a pipeline fixed U-shaped clamp.

[0014] In a further embodiment, the flange fixing structure is connected to the medium flow collection pipeline;

[0015] The flange fixing structure comprises a fixed connecting plate fixed on the connecting valve group, a flange fixing frame is fixed on the bottom plane of the fixed connecting plate, and the flange fixing frame is fixedly connected to the flange plates at both ends of the medium flow collection pipeline.

[0016] In a further embodiment, a Pitot tube may be connected between the medium buffer flow guide tube and the medium flow collection pipeline.

[0017] In a further embodiment, the logic execution module performs the following process:

[0018] The flow protection switch is powered on, and the initialization is to detect whether the flow energy conversion module and the sensor are normal; after the detection is passed, it enters the operation mode to judge:

[0019] If it is in the configuration mode, the configuration parameter management module will take over the subsequent process: the configuration parameter management module accepts the user's operating parameter information, and when the flow protection switch enters the operating state, it manages the energy conversion source mode, energy storage medium type and display energy saving mode to realize the configuration of energy saving function and operating energy parameters;

[0020] If it is in normal working state, it will enter the data processing flow: collect sensor data function, two acquisition channels, respectively collect a predetermined amount of transient data, send the transient data to the data processing function, and perform data time domain analysis and frequency domain analysis;

[0021] After differential pressure calculation and pressure and flow conversion, the output value calculation result is sent to the display function for threshold judgment: if it exceeds the initially set limit, the limit alarm function drives the solid-state relay to output the switch value, and then loops the main program to judge the operation mode.

[0022] In a further embodiment, the main body of the sensor data acquisition function outputs a basic time domain function F(X)=fir(f(x)); wherein F(X) is an output data series, f(x) is a discrete time domain series of raw sensor data, and fir(f(x)) is a filter value range data processing function;

[0023] fir(f(x))=(k*x t +(1-k)x t-1 )*a c

[0024] Where, k is the switch instrument coefficient, which is calculated based on different media and media flow characteristics; x t 、x t-1 are two time-continuous raw data; a c is the environmental factor compensation coefficient.

[0025] In a further embodiment, the data processing function is used to output the effective flow value Q n :

[0026]

[0027] In the formula, A is the output coefficient, B is the diameter ratio, K is the expansion correction coefficient, Ap t is the time domain pressure difference between the two channels of the medium acquisition sensor, p is the medium density, F is the dynamic frequency correction coefficient, g is the gravity acceleration, and Ah is the pressure sampling tube correction coefficient.

[0028] Beneficial effect: The present invention proposes a two-wire flow protection switch, which realizes accurate measurement and intelligent protection of flow by integrating a low-power control acquisition circuit module, a configurable control switch output module, an energy collection and conversion management module, and multiple combination flow measurement accessories. At the same time, it reduces equipment power consumption, simplifies wiring, maintains the two-wire working mode on site, and improves the overall performance and reliability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 1 is a structural diagram of a flow switch in the form of a pipe clamp structure in an embodiment.

[0030] Figure 2 It is a schematic diagram of the exploded parts of the flow switch in the form of a pipe clamp structure in the embodiment.

[0031] Figure 3 It is a structural diagram of a flow switch with a flange fixed structure in an embodiment.

[0032] Figure 4 It is a schematic diagram of the exploded parts of the flow switch with flange fixed structure in the embodiment.

[0033] Figure 5 It is a structural diagram of a flow switch with a pitot structure in an embodiment.

[0034] Figure 6 It is a schematic diagram of the exploded parts of the flow switch with a pitot structure in the embodiment.

[0035] Figure 7 This is the working principle diagram of the flow energy conversion module.

[0036] Figure 8 It is a flowchart of the workflow of the logic execution module.

[0037] The reference numerals in the figure are: switch control instrument module 1, connecting valve group 2, medium buffer guide pipe 3, sewage outlet 4, fixed connecting plate 5, flow energy conversion module 6, fixed support frame 701, flange fixing frame 702, fixed connecting bracket 703, pipeline fixing U-shaped clamp 801, medium flow collection pipeline 9, and Pitot tube 10. DETAILED DESCRIPTION

[0038] In the following description, a large number of specific details are provided to provide a more thorough understanding of the present invention. However, it is apparent to those skilled in the art that the present invention can be implemented without one or more of these details. In other examples, in order to avoid confusion with the present invention, some technical features known in the art are not described.

[0039] Figure 1 and Figure 2The assembly form of a flow switch in the form of a pipe clamp structure disclosed in this embodiment is composed of a switch control instrument module 1, a connecting valve group 2, a medium buffer guide pipe 3, a sewage outlet 4, a fixed connecting plate 5, a flow energy conversion module 6, a fixed support frame 701, a pipe fixed U-shaped clamp 801, and a medium flow collection pipeline 9.

[0040] The switch control instrument module 1 integrates a low-power control acquisition circuit module, a configuration-based control switch output module, and an energy collection and conversion management module. The switch control instrument module 1 is connected to the connecting valve group 2. The function of the connecting valve group 2 is to introduce the flow medium into the sensor of the acquisition circuit module respectively. The inlet of the connecting valve group 2 is connected to the medium buffer guide tube 3. The sewage outlet 4 is used for exhaust and sewage discharge, and is used for switch installation or maintenance. The fixed connecting plate 5 connects the fixed support frame 701 and the pipeline fixed U-shaped clamp 801. The flow energy conversion module 6 connects the medium buffer guide tube 3 and the medium flow collection pipeline 9.

[0041] Figure 3 and Figure 4 The assembly form of the flow switch with a flange fixed structure disclosed in this embodiment is composed of a switch control instrument module 1, a connecting valve group 2, a medium buffer guide pipe 3, a sewage outlet 4, a fixed connecting plate 5, a flow energy conversion module 6, a flange fixing frame 702, and a medium flow collection pipeline 9.

[0042] The switch control instrument module 1 integrates a low-power control acquisition circuit module, a configuration-based control switch output module, and an energy collection conversion management module. The switch control instrument module 1 is connected to the connecting valve group 2. The function of the connecting valve group 2 is to introduce the flow medium into the sensor of the acquisition circuit module respectively. The inlet of the connecting valve group 2 is connected to the medium buffer guide pipe 3. The sewage outlet 4 serves as an exhaust and sewage discharge port and is used for switch installation or maintenance. The fixed connecting plate 5 connects the flange fixing frame 702 and the pipeline flange screws. The flow energy conversion module 6 is connected to the medium buffer guide pipe 3 and the medium flow collection pipeline 9.

[0043] Figure 5 and Figure 6 The assembly form of the flow switch of the Pitot structure form disclosed in this embodiment is composed of a switch control instrument module 1, a connecting valve group 2, a sewage outlet 4, a fixed connecting bracket 703, a medium buffer guide tube 3, a Pitot module (integrated with a flow energy conversion module 6), and a medium flow collection pipeline 9.

[0044] The switch control instrument module 1 mainly integrates a low-power control acquisition circuit module, a configuration-based control switch output module, and an energy collection conversion management module. The switch control instrument module 1 is connected to the connecting valve group 2. The function of the connecting valve group 2 is to introduce the flow medium into the sensor of the acquisition circuit module respectively. The inlet of the connecting valve group 2 is connected to the medium buffer guide pipe 3. The sewage outlet 4 plays the role of exhaust and sewage discharge, and is used for switch installation or maintenance. The fixed connecting bracket 703 is connected to the medium buffer guide pipe 3. The pitot tube 10 connects the medium buffer guide pipe 3 and the medium flow collection pipeline 9.

[0045] Implementation overview: First, design and install the energy conversion module at the appropriate position of the fluid channel to ensure that it can efficiently convert fluid energy into electrical energy. Then, install the flow acquisition sensor drainage tube to the appropriate position to ensure that the fluid state can be accurately sensed. The control circuit adopts an ultra-low power design and combines a microprocessor to implement an intelligent configurable logic control algorithm to optimize energy utilization and improve control accuracy. The execution alarm node output is configured according to actual needs to achieve precise control of the fluid and logical protection actions.

[0046] In the specific implementation, the design selects and assembles an ultra-low power consumption intelligent flow acquisition integrated module to ensure that the power consumption can be maintained at extremely low levels in the working state. Then, the flow measurement auxiliary device and the pressure acquisition module are integrated with the intelligent pressure flow acquisition integrated module through the pressure collection pipe through the reasonably selected differential pressure collection point and the energy conversion installation position. The flow is accurately measured and converted into a digital signal through the compensation algorithm. The intelligent control logic operation module converts the digital signal processing into the flow mean value. The intelligent control logic operation module performs a new type of device for the corresponding solid-state switch protection action according to the preset flow threshold, time parameters, etc. by loading the configured threshold. A variety of functional controls are applied, such as cutting off the fluid supply, issuing an alarm signal, etc. An energy conversion module, such as a micro-turbine generator or a piezoelectric material converter, is set at a specific location to convert the kinetic energy or potential energy generated by the fluid flow into electrical energy. At the same time, remote communication and data transmission with the host computer can be realized through a two-wire communication interface, which is convenient for real-time monitoring and fault diagnosis.

[0047] The switch has the advantages of low power consumption, high measurement accuracy, high intelligence and simple wiring. Its components include energy conversion module, sensor, control circuit module and logic execution module. It is characterized by: using ultra-low power micro-control technology, combined with the energy conversion collection management module, it can convert the energy generated by fluid flow or other kinetic energy into electrical energy, and provide power for sensors, acquisition modules, control modules and alarm control modules, so that the device can seamlessly replace other non-intelligent protection devices and enhance the digital control capability of the overall process system.

[0048] Figure 7The working principle of the flow energy conversion module 6 is shown. The energy main control module is responsible for the management of the energy conversion system, external power supply management and energy source configuration. The energy conversion module is responsible for obtaining the corresponding energy from the energy source, converting the corresponding energy into electrical energy and storing it in the energy storage module to supply electrical energy to the flow switch. The energy source manages the channel of the energy source and sets the type of energy used: light energy sensing (indoor light, sunlight), electromagnetic energy (electromagnetic induction) and stress energy (pressure, flow difference).

[0049] Figure 8 The following shows the workflow of the logic execution module. Initialization process example: S1-S2-S3-S4-S5-S6.

[0050] Example flow of the loop operation process:

[0051] 1. There is a display loop logic: S5-S6-S7-S8-S9-S10-S11-S12-S13-S5.

[0052] 2. No display loop logic: S5-S6-S7-S8-S9-S10-S11-S13-S5.

[0053] The software program starts running and enters the initialization program segment (the main function is the bootstrap self-test of the main program after the flow switch is powered on). The initialization test has two parts. One is whether the energy conversion module is working and whether the parameters of the connected energy source are normal (whether the converted voltage is normal, whether the energy storage capacitor C value is normal, whether the working circuit is normal); the other is the status of the sensor (whether the sensors at the two ends of the collection guide pipe have numerical feedback, and the difference calculation parameters). After the test is passed, it enters the operation mode judgment. The cyclic operation process flow contains two states, one is in the configuration mode state, which is used during the initial installation or debugging experiment of the equipment. When entering this state, the main program is taken over by the configuration parameter management module and accepts the user's operation parameter information (which can be input through buttons or upper computer software configuration). When the switch enters the operation state, the configuration parameter management module manages the energy conversion source mode, energy storage medium type and display energy saving mode to realize the configuration of energy saving functions and operation energy parameters. If the operation mode is judged, the main program will enter the data processing, data processing (including transient data and process data processing), sensor data acquisition function (see formula 1), two acquisition channels, respectively collect a certain amount of transient data, send the data to the data processing function (see formula 2), perform data time domain analysis and frequency domain analysis, and perform related sub-item operations and related operations on the two aspects of the data, including pressure difference operation, pressure and flow conversion, output value data compensation coefficient operation, and output the data to the display function (the function is to display the required value according to the configuration setting), and perform threshold judgment. If it exceeds the initial limit, the limit alarm function drives the solid-state relay to output the switch value, and then the main program is circulated to the operation mode judgment. The main program runs according to this logic.

[0054] The main function of the sensor data acquisition function outputs the basic time domain function F(X)=fir(f(x));

[0055] F(X) is the output data series; f(x) is the discrete time domain series of the original sensor data, and fir(f(x)) is the filter range data processing function.

[0056] fir(f(x))=(k*x t +(1-k)x t-1 )*a c Formula (1)

[0057] Where, k is the switch instrument coefficient, which is calculated based on different media and media flow characteristics; x t 、x t-1 are two time-continuous raw data; a c is the environmental factor compensation coefficient.

[0058] The data processing function is used to output the effective value of flow Q n :

[0059]

[0060] In the formula, A is the output coefficient, B is the diameter ratio, K is the expansion correction coefficient, Ap t is the time domain pressure difference between the two channels of the medium acquisition sensor, p is the medium density, F is the dynamic frequency correction coefficient, g is the gravity acceleration, and Ah is the pressure sampling tube correction coefficient.

[0061] In summary, the present invention can achieve at least the following technical effects:

[0062] (1) The use of ultra-low power chip instruments realizes the digital conversion and collection of flow. By optimizing the layout of flow collection measurement points and adopting low-power components and calculation logic mechanisms, the working power consumption of the equipment is significantly reduced, and an intelligent and configurable flow protection switch is realized.

[0063] (2) Based on the combination with a variety of flow measurement accessory mechanical devices, the reasonable selection and calculation of upstream and downstream flow collection measurement points on the accessories can stably and accurately reflect the flow changes of the fluid.

[0064] (3) The present invention proposes an energy conversion and redundant power management module that utilizes pressure energy to convert into electrical energy. This module collects differential pressure energy, strain potential energy, and energy from signals, and converts these energies into electrical energy for use by various power modules of the pressure protection switch, thereby realizing a multi-source power redundancy function.

[0065] (4) Two-wire switch interface directly replaces two-wire mechanical switches and traditional electronic switches, which simplifies wiring, reduces installation costs, and supports remote communication and data transmission.

[0066] The above technical solution proposed by the present invention can be widely applied to the field of industrial automation control to improve the overall performance, intelligent digitalization level and reliability of the system.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A two-wire flow protection switch, characterized in that: It includes a switch control instrument module, a connecting valve group, a medium buffer guide pipe, a sewage outlet, a flow energy conversion module, and a medium flow collection pipeline; Wherein, the switch control instrument module is electrically connected to the connection valve group; the switch control instrument module is embedded with a sensor and a logic execution module; One end of the medium buffer flow guide pipe is connected to the medium flow collection pipeline through the flow energy conversion module, and the other end is connected to the connection valve group; The medium flow in the medium buffer guide pipe is introduced into the switch control instrument module by connecting the valve group; The flow energy conversion module converts the energy generated by the flow of the medium into electrical energy to supply power to the switch control instrument module; The sewage outlet is arranged at one side of the connecting valve group; and the medium flow collection pipeline is fixed at the lower part of the connecting valve group.

2. The two-wire flow protection switch according to claim 1 is characterized in that: The flow energy conversion module includes a micro-turbine generator or a piezoelectric material conversion controller.

3. The two-wire flow protection switch according to claim 1 is characterized in that: The sensor includes at least one of a flow sensor, a temperature sensor and a pressure sensor.

4. The two-wire flow protection switch according to claim 1, characterized in that: Fixed on the medium flow collection pipeline through the pipeline clamp structure; The pipeline clamp structure includes a fixed connecting plate fixed on the connecting valve group, and a fixed support frame is fixed on the bottom plane of the fixed connecting plate. The medium flow collection pipeline is abutted against the fixed support frame and fixed by a pipeline fixing U-shaped clamp.

5. The two-wire flow protection switch according to claim 1, characterized in that: Connect with the medium flow collection pipeline through the flange fixing structure; The flange fixing structure comprises a fixed connecting plate fixed on the connecting valve group, a flange fixing frame is fixed on the bottom plane of the fixed connecting plate, and the flange fixing frame is fixedly connected to the flange plates at both ends of the medium flow collection pipeline.

6. The two-wire flow protection switch according to claim 1, characterized in that: A Pitot tube can be connected between the medium buffer guide tube and the medium flow collection pipeline.

7. The two-wire flow protection switch according to any one of claims 1 to 6, characterized in that: The logic execution module executes the following process: The flow protection switch is powered on, and the initialization is to detect whether the flow energy conversion module and the sensor are normal; after the detection is passed, it enters the operation mode to judge: If it is in the configuration mode, the configuration parameter management module will take over the subsequent process: the configuration parameter management module accepts the user's operating parameter information, and when the flow protection switch enters the operating state, it manages the energy conversion source mode, energy storage medium type and display energy saving mode to realize the configuration of energy saving function and operating energy parameters; If it is in normal working state, it will enter the data processing flow: collect sensor data function, two acquisition channels, respectively collect a predetermined amount of transient data, send the transient data to the data processing function, and perform data time domain analysis and frequency domain analysis; After differential pressure calculation and pressure and flow conversion, the output value calculation result is sent to the display function for threshold judgment: if it exceeds the initially set limit, the limit alarm function drives the solid-state relay to output the switch value, and then loops the main program to judge the operation mode.

8. The two-wire flow protection switch according to claim 7, characterized in that: The main body of the sensor data acquisition function outputs a basic time domain function F(X)=fir(f(x)); wherein F(X) is an output data series, f(x) is a discrete time domain series of raw sensor data, and fir(f(x)) is a filter value range data processing function; for(f(x))=(k*x t +(1-k)x t-1 )*a c Where, k is the switch instrument coefficient, which is calculated based on different media and media flow characteristics; x t 、x t-1 are two time-continuous raw data; a c is the environmental factor compensation coefficient.

9. The two-wire flow protection switch according to claim 7, characterized in that: The data processing function is used to output the effective value of the flow rate Q n : In the formula, A is the output coefficient, B is the diameter ratio, K is the expansion correction coefficient, Ap t is the time domain pressure difference between the two channels of the medium acquisition sensor, p is the medium density, F is the dynamic frequency correction coefficient, g is the gravity acceleration, and Ah is the pressure sampling tube correction coefficient.

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