High-energy-consumption industry load regulation safety constraint and remote regulation method and system

Abstract

The invention discloses a high-energy-consumption industry load regulation safety constraint and remote regulation method and system, and relates to the technical field of load regulation, and the method comprises the steps: collecting the operation data of a rectifier unit in real time; designing a remote load regulation and control strategy; constructing a safety threshold system according to the collected operation data; and implementing a remote regulation control strategy according to the remote load regulation strategy and the safety threshold system. According to the invention, a rectification unit gear switch adjusting scheme can be optimized, so that stable operation of important electric appliances of a user is ensured. Through deep theoretical research and specific practice schemes, a practical and efficient load regulation and control scheme and equipment are provided for the high-energy-consumption industry, accurate remote regulation and control of the voltage of electrical equipment are achieved, the stability and efficiency of an electric power system are improved, and safe and stable operation of important electric appliances is guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of load regulation, and in particular to a method and system for safety constraint and remote regulation of load regulation in high energy consumption industries. Background Art

[0002] The existing load control technologies for high-energy-consuming industries are mainly based on rectifier unit gear switch adjustment, remote control methods, hardware design solutions, etc. However, although these technologies have solved the needs of power control in high-energy-consuming industries to a certain extent, there are still many problems and challenges, mainly including the following aspects:

[0003] 1. Adjustment of the rectifier unit gear switch:

[0004] Regulation accuracy: In actual use, existing rectifier unit gear switch regulation solutions often have the problem of insufficient regulation accuracy. For example, some solutions may produce fluctuations in the process of voltage and current regulation that are not suitable for the load, thus affecting the stability of the entire system.

[0005] Adjustment speed: The existing rectifier unit gear switch adjustment scheme, especially the phase control adjustment scheme and PWM adjustment scheme, needs to be improved in terms of rapid response. This is mainly manifested in that when the load changes quickly, the adjustment speed cannot keep up, resulting in reduced voltage and current stability.

[0006] Adjustment complexity: Existing rectifier unit gear switch adjustment schemes usually require complex calculations and settings of various parameters, which increases the difficulty and complexity of adjustment.

[0007] Rectifier wear: Each gear change may cause more serious rectifier wear and reduce its service life.

[0008] 2. Remote control method:

[0009] Communication delay: Existing remote control methods usually rely on communication networks. However, in some applications, communication delays may seriously affect the stability and efficiency of the entire system.

[0010] Communication security: Remote control methods may have communication security risks, including data leakage, illegal tampering, malicious attacks and other issues.

[0011] 3. Hardware design:

[0012] System cost: Existing hardware design solutions, including different remote adjustment switches, control modules and other components, usually increase the cost of the entire system, and quality and performance are positively correlated with price.

[0013] Maintainability: Some special components involved in the hardware design may require professional maintenance, which increases shipping costs and maintenance difficulty.

[0014] Compatibility: Existing hardware design solutions may have compatibility issues, that is, the different components used may not be fully compatible, which not only brings difficulties to system integration, but may also affect the stability and reliability of the system.

[0015] Hardware vulnerability: Due to the harsh working environment of some devices, the hardware may be vulnerable, resulting in reduced system operating stability.

[0016] All of the above shortcomings have limited the application of existing technologies in high-energy-consuming industries to a certain extent. Future technological development should focus on these issues and seek more accurate, fast, safe, economical and reliable control solutions. Summary of the invention

[0017] In view of the above-mentioned problems, the present invention is proposed.

[0018] Therefore, the problem to be solved by the present invention is: how to solve the problem of adjustment accuracy and speed of the rectifier unit gear switch in the existing method.

[0019] To solve the above technical problems, the present invention provides the following technical solutions: a safety constraint and remote control method for load regulation in high-energy-consuming industries, including real-time collection of operating data of rectifier units; designing a remote load regulation strategy; building a safety threshold system based on the collected operating data; and implementing a remote adjustment control strategy based on the remote load regulation strategy and the safety threshold system.

[0020] As a preferred solution of the method for safety constraint and remote control of load control in high-energy-consuming industries described in the present invention, the operating data of the rectifier unit includes voltage, current, power, resistance and temperature.

[0021] As a preferred solution of the safety constraint and remote control method for load control in high energy consumption industries of the present invention, the design of remote load control strategy includes analyzing the influence of the gear switch of the rectifier unit on the current and voltage to design a remote load control strategy; calculating the output voltage of the rectifier is expressed as:

[0022] V out =V in *D uty

[0023] Among them, V out is the output voltage, V in is the input voltage of the rectifier, D uty is the duty cycle; the output current of the rectifier is calculated as:

[0024] I out =V in / R load

[0025] Among them, I out is the output current, R load is the load resistance.

[0026] As a preferred solution of the high energy consumption industry load control safety constraint and remote control method of the present invention, wherein: the design of the remote load control strategy also includes calculating the voltage stability and frequency stability; the voltage stability is expressed as:

[0027] ΔV=|V max -V min | / V nominal

[0028] Where ΔV is the voltage stability, V max is the maximum voltage, V min is the minimum voltage, V nominal is the rated voltage; the frequency stability is expressed as:

[0029] Δf=|f max -f min | / f nominal

[0030] Where Δf is the frequency stability, f max is the maximum frequency, f min is the minimum frequency, f nominal is the rated frequency; load control is performed through the gear switch adjustment scheme.

[0031] As a preferred solution of the load control safety constraint and remote control method for high energy consumption industries of the present invention, the safety threshold includes analyzing the operating boundary conditions of the rectifier unit control to set the safety threshold; the power output of the main power supply line of the high energy consumption industry user is limited according to the DC side voltage, and is supplemented by the branch power supply line, which is expressed as:

[0032] P b (V,t)=P e (V,U dc ,t)+P m (t)

[0033]

[0034] Among them, P b is the main power supply line power, P e is the power of the electrical equipment, P m is the power of the branch power supply line, V is the load, U is the load dcis the output voltage of the electrical equipment, E b From time t I Total power consumption to t2;

[0035]

[0036] The safety threshold is set at α<A<β.

[0037] As a preferred solution of the load control safety constraint and remote control method for high energy consumption industries of the present invention, the safety threshold also includes a lower limit of the threshold set during adjustment. When the upper limit of the threshold is reached, an alarm is triggered and the corresponding switch gear adjustment is started. The discrimination adjustment is expressed as:

[0038] P load (t) = P sub (t)+P ESS (t)

[0039]

[0040] Among them, P load is the load power of the main power supply line, P sub The maximum power provided by the grid, P ESS is the maximum power of the electrical equipment, E load From time t I The maximum power consumption to t2; the safety threshold system includes a voltage threshold, a current threshold, a temperature threshold and a dynamic response threshold.

[0041] As a preferred solution of the high-energy-consuming industry load control safety constraint and remote control method described in the present invention, the implementation of the remote control strategy includes hardware design based on the remote load control strategy and the safety threshold system, and gear reading and gear adjustment.

[0042] Another object of the present invention is to provide a system for load control safety constraints and remote control methods for high-energy-consuming industries, which can solve the problems of load control safety constraints and remote control methods for high-energy-consuming industries by constructing a load control safety constraints and remote control system for high-energy-consuming industries.

[0043] To solve the above technical problems, the present invention provides the following technical solutions: a high-energy-consuming industry load control safety constraint and remote control system, including a data acquisition module, a remote load control module, a safety threshold module and a remote adjustment module; the data acquisition module is used to collect the operating data of the rectifier unit in real time; the remote load control module is used to design a remote load control strategy; the safety threshold module is used to build a safety threshold system based on the collected operating data; the remote adjustment module is used to implement a remote adjustment control strategy based on the remote load control strategy and the safety threshold system.

[0044] A computer device includes a memory and a processor, wherein the memory stores a computer program, and when the processor executes the computer program, the steps of the above-mentioned method for safety constraints and remote control of load control in high-energy-consuming industries are implemented.

[0045] A computer-readable storage medium stores a computer program, which, when executed by a processor, implements the steps of the above-mentioned high-energy-consuming industry load regulation safety constraint and remote regulation method.

[0046] The beneficial effects of the present invention are as follows: the safety constraint and remote control method for load regulation in high-energy-consuming industries provided by the present invention conducts an in-depth analysis of the influence of the rectifier unit gear switch on the current and voltage, enriches the theoretical research on load regulation in high-energy-consuming industries, and helps to optimize the rectifier unit gear switch adjustment scheme, thereby ensuring the stable operation of important electrical appliances of users.

[0047] An operating boundary condition analysis method for rectifier unit control was established, and detailed explanations were given through specific examples to clarify the specific strategies and steps for load control of users in high-energy-consuming industries, which is conducive to guiding practical operations.

[0048] A safety threshold selection model and a safety threshold system were proposed, which properly handled the relationship between the power of the power supply line and the power of the electrical equipment, ensuring the stable operation of the electrical equipment.

[0049] A remote on-load voltage regulation rectifier unit gear switch adjustment hardware device is designed, taking into account the coordinated work of various parts, realizing remote voltage regulation and improving the working efficiency and safety of the rectifier unit.

[0050] System testing and tuning ensure the performance and reliability of the entire system.

[0051] Through in-depth theoretical research and specific practical plans, a practical and efficient load control solution and equipment is provided for high-energy-consuming industries, which realizes precise remote control of the voltage of electrical equipment, improves the stability and efficiency of the power system, and ensures the safe and stable operation of important electrical appliances. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative labor.

[0053] Figure 1 A flow chart of a method for safety constraints and remote control of load control in high-energy-consuming industries provided in the first embodiment of the present invention.

[0054] Figure 2 A rectifier transformer winding diagram for parallel operation of the high energy consumption industry load control safety constraint and remote control method provided in the first embodiment of the present invention.

[0055] Figure 3 A diagram showing the design concept of a remote on-load voltage regulation hardware device for a high-energy-consuming industry load regulation safety constraint and remote regulation method provided in the first embodiment of the present invention.

[0056] Figure 4 The overall principle diagram of the terminal control gear adjustment of the high-energy-consuming industry load control safety constraint and remote control method provided in the first embodiment of the present invention.

[0057] Figure 5 A design diagram of a rectifier unit gear position reading access method for a high-energy-consuming industry load control safety constraint and remote control method provided in the first embodiment of the present invention.

[0058] Figure 6 A design diagram of a rectifier unit gear adjustment control access method for a high-energy-consuming industry load control safety constraint and remote control method provided in the first embodiment of the present invention.

[0059] Figure 7 A structural diagram of a load control safety constraint and remote control system for high-energy-consuming industries provided in the second embodiment of the present invention.

[0060] Figure 8 The overall design framework diagram of the rectifier unit access in the electrolytic aluminum industry for the high-energy-consuming industry load control safety constraint and remote control method provided in the third embodiment of the present invention. DETAILED DESCRIPTION

[0061] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0062] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0063] Example 1, reference Figure 1 to Figure 6 , which is the first embodiment of the present invention, provides a load control safety constraint and remote control method for high-energy-consuming industries, including: real-time collection of operating data of rectifier units; designing a remote load control strategy; building a safety threshold system based on the collected operating data; and implementing a remote adjustment control strategy based on the remote load control strategy and the safety threshold system.

[0064] Shift switch regulation: This technology is based on power electronic rectifiers. By changing the working state of the rectifier, the current and voltage are further adjusted to adjust the output of the rectifier unit. Shift switch regulation mainly depends on the state of the rectifier unit and the load requirements, and there are many different regulation schemes to choose from, such as phase control regulation scheme, pulse width modulation (PWM) regulation scheme and multi-pulse regulation scheme.

[0065] Safety threshold selection: In order to ensure the safety and stability of the system, it is very important to select the appropriate safety threshold. Affected by multiple factors such as current, voltage, temperature and system response, it is particularly critical to establish a comprehensive safety threshold system. The safety threshold not only avoids overloading or underloading of electrical equipment, but also can serve as an effective load regulation tool.

[0066] Remote control and communication: To achieve remote load control, this solution uses advanced communication technology. In the hardware design, a device with key components such as remote control switch, BCD decoder, control module, output module and communication module is proposed. The device can receive remote signals, adjust the voltage level, and achieve remote control communication.

[0067] Specific technical measures and methods:

[0068] Threshold analysis and setting: In the traditional regulation mode, a steady-state threshold is generally used, that is, a fixed limit threshold is set, and an alarm is issued or a protection action is activated when the parameter crosses this threshold. However, in this system, a dynamic threshold setting method is adopted. Under the conditions of changes in operating parameters such as load and ambient temperature, the threshold is adjusted accordingly to adapt to the actual working conditions.

[0069] Remote control and adjustment: This technology uses advanced communication technology and protocols to achieve remote control and adjustment of load control equipment. Through the control signal transmitted through the network, the gear switch of the rectifier unit can be adjusted in real time to change the output voltage to meet the real-time load needs.

[0070] Intelligent control of rectifier equipment: Through the intelligent upgrade of rectifier equipment, high-performance embedded microprocessors and advanced control algorithms such as PID algorithm and fuzzy logic control algorithm can be used to achieve high-precision control of rectifier equipment. At the same time, intelligent equipment can realize self-diagnosis and fault alarm functions to detect and deal with possible problems at an early stage.

[0071] Collaborative control and dispatching: In complex power systems, the collaborative work of multiple rectifiers, such as interlocking control and dispatching of rectifier units, can achieve load regulation with a wider range and higher precision. At the same time, collaborative work also makes the system more fault-tolerant and robust.

[0072] Data collection and analysis: Through big data and artificial intelligence technology, real-time collection, analysis and feedback of system operation data can be achieved, forming a complete decision support system to assist system operators in making better operation and scheduling decisions.

[0073] Based on the implementation principles of these technologies, a set of solutions for load control safety constraints and remote control in high-energy-consuming industries has been developed. This solution can not only meet the long-term and high-load working requirements of high-energy-consuming industries, but also improve the efficiency and economy of the entire power system operation while ensuring the safe and stable operation of equipment and systems. At the same time, with the help of advanced communication and control technologies, remote real-time monitoring of the operating status of equipment and systems is achieved, which facilitates maintenance personnel to discover and solve problems in a timely manner, avoiding or reducing losses caused by equipment failures.

[0074] S1, real-time collection of operating data of the rectifier unit;

[0075] The operating data of the rectifier unit includes voltage, current, power, resistance and temperature, and the collected data is analyzed.

[0076] S2. Design remote load control strategy.

[0077] The impact of the rectifier unit gear switch on current and voltage.

[0078] Rectifiers are power electronic devices that convert alternating current (AC) into direct current (DC) and are widely used in various industries and power systems. The gear switch regulation technology changes the working state of the rectifier to adjust the voltage and current of the output DC power to meet the needs of different loads. The gear switch regulation scheme of the rectifier unit is a key technology for adjusting the current and voltage output in the power system, which is crucial to ensure the stable operation of the user's important electrical appliances. This section aims to analyze the impact of different rectifier unit gear switch regulation schemes on the current and voltage of the user's important electrical appliances.

[0079] S2.1. Characteristics of the rectifier unit gear switch adjustment scheme.

[0080] Phase control adjustment scheme: The output DC voltage is changed by adjusting the phase angle of the rectifier input AC voltage. This scheme is suitable for application scenarios with high requirements for current and voltage regulation accuracy.

[0081] Pulse Width Modulation (PWM) regulation scheme: A method of adjusting the output voltage and current by changing the switching frequency and duty cycle of the rectifier switching elements. This scheme is characterized by being able to provide higher efficiency and lower output voltage ripple.

[0082] Multi-pulse regulation scheme: By increasing the number of rectifier bridges and changing their phase angles, the quality of the output voltage and system efficiency can be improved. This scheme is suitable for high-power application scenarios such as high-energy-consuming industries.

[0083] Calculation of the influence of the rectifier unit gear switch on current and voltage:

[0084] The most direct effect of the position switch is the control of the output voltage and current. In the working characteristics of the position switch, a basic formula is:

[0085] V out =V in *D uty

[0086] Among them, V out is the output voltage, V in is the input voltage of the rectifier, D uty is the duty cycle, which indicates the proportion of time the switch is in the on state in one cycle. Given an input voltage V in and duty cycle D uty , we can calculate the output voltage V out .

[0087] I out =V in / R load

[0088] Among them, I out is the output current, R load is the load resistance. By adjusting the duty cycle D uty , can change the output voltage V out , thus affecting the output current I out .

[0089] S2.2、Analysis of the impact on users’ important electrical appliances:

[0090] Current impact: Different regulation schemes have a significant impact on the smoothness and stability of the output current. For example, the PWM regulation scheme can reduce current fluctuations and protect electrical appliances from current shocks due to its high-frequency switching characteristics. Although phase control and multi-pulse regulation schemes can effectively control current, they may produce large current fluctuations under certain conditions.

[0091] Voltage impact: Voltage stability is a key indicator for evaluating the performance of rectifier units. The PWM regulation scheme can effectively reduce voltage ripple and improve voltage stability. The phase control regulation scheme has a faster voltage adjustment speed when the load changes, but it may cause voltage fluctuations. The multi-pulse regulation scheme reduces voltage ripple by increasing the number of phases of the output voltage, which is suitable for application scenarios with high voltage quality requirements.

[0092] It mainly affects the current and voltage stability of important electrical appliances of users. Stability can be measured by voltage stability and frequency stability. The relevant expression formula is as follows:

[0093] Voltage stability is expressed as:

[0094] ΔV=|V max -V min | / V nominal

[0095] Where ΔV is the voltage stability, V max is the maximum voltage, V min is the minimum voltage, V nominal is the rated voltage.

[0096] Frequency stability is expressed as:

[0097] Δf=|f max -f min | / f nominal

[0098] Where Δf is the frequency stability, f max is the maximum frequency, f min is the minimum frequency, f nominal is the rated frequency.

[0099] If the voltage and frequency can maintain good stability, it can be regarded as a good influence on the important electrical appliances of the users. If the voltage and frequency fluctuate too much, it will have an adverse effect on the electrical equipment and may damage the stability and life of the equipment.

[0100] The gear switch adjustment schemes of different rectifier units have a significant impact on the current and voltage of important electrical appliances of users. When selecting a suitable adjustment scheme, it is necessary to comprehensively consider the characteristics of the load, the efficiency of the system, and the requirements for current and voltage stability. The PWM adjustment scheme is suitable for most application scenarios due to its high efficiency and excellent voltage and current control performance. The phase control adjustment scheme is more suitable for applications that require fast response. The multi-pulse adjustment scheme shows its advantages in situations with high power and high voltage quality requirements. By reasonably selecting and optimizing the gear switch adjustment scheme of the rectifier unit, the stability and efficiency of the power system can be effectively improved, and the safe and stable operation of important electrical appliances can be guaranteed.

[0101] S3. Build a safety threshold system based on the collected operation data.

[0102] Taking the on-site survey data of a certain aluminum electrolytic plant as an example, there are two 220kV substations supplying power, with an operating capacity of 573MW and an average load of 330MW. The main operating load is the aluminum electrolytic DC electrolytic cell production line, with a total of 248 electrolytic cells, which are powered by 6 sets of rectifier units.

[0103] The rectifier unit operates at 60% of the rated capacity (economical and safe operating load) on a daily basis, that is, the operating capacity of each rectifier unit is about 51,000 kVA. The six rectifier units can actually reduce the load by about 5,000 kW for each gear reduction. The adjustment process takes 1-2 minutes per gear from issuing instructions to completing the gear reduction. After receiving the gear change feedback, the next gear is adjusted. The gear adjustment is carried out step by step in the order of adjusting one gear, stabilizing one gear, and then adjusting the next gear. Within 30 minutes, the load can be reduced by about 100,000 kW, accounting for 30% of the operating capacity, and can be maintained for up to 120 minutes; in extreme cases, it can be reduced to 1 gear, and the total load is reduced to about 5,000 kW, which can be maintained for up to 60 minutes; remote control only carries out downshifting control, and upshifting is controlled by local users.

[0104] When the load reduction by on-load voltage regulation fails to reach the target, the load management system will send the status of the execution of the load control plan and the subsequent execution application to the superior power grid dispatching and control agency (Kunming Local Dispatching). Since Kunming Local Dispatching has realized the remote control tripping function of the circuit breaker on the power supply substation (500kV Qidian substation, 220kV Guolin substation), the tripping operation can be performed by the dispatching agency or the centralized control station, without the need to repeatedly invest in the installation of load control equipment (for the circuit breaker at the head end that has not yet realized the dispatching remote control tripping function, the load control equipment needs to be installed on site to realize the control function). After the dispatching agency receives the voltage control load application from the load management department, the dispatching agency orders the user to exit the backup power supply automatic device, and remotely disconnects the 500kV Qidian substation 220kV Qi Aluminum I circuit, 220kV Qi Aluminum II circuit and 220kV Guolin substation 220kV Guo Aluminum I circuit, 220kV Guo Aluminum II circuit substation side circuit breaker, suspends the power supply to the user's entire station, and ensures that the load voltage drops to the required level; the load management system issues a supply guarantee warning notice to the user end, notifying the user in advance to be prepared and shut down the production line to achieve the supply guarantee purpose.

[0105] Based on the above analysis, the equivalent circuit of the rectifier unit is composed of a rectifier transformer and a rectifier. The windings of the rectifier transformers running in parallel are as follows: Figure 2 shown.

[0106] Rectifier unit output no-load voltage U dc0 There is a certain proportional relationship with the grid-side voltage value as follows:

[0107]

[0108] Among them, U dc0 is the output no-load voltage of the rectifier unit, P is the number of pulses, U2 is the valve side line voltage value, U1 is the medium voltage grid line voltage value, N is the transformation ratio of the transformer primary to secondary side, U IN is the rated value of the medium voltage network line voltage, and δ is the fluctuation rate. The output no-load voltage of the rectifier unit is:

[0109] U dc0 ≈1.41NU1

[0110] The load regulation strategy for electrolytic aluminum should be based on regulation and supplemented by control. That is, first use Plan 1 to remotely adjust the gear position of the rectifier unit to achieve a maximum voltage drop of one-third of the operating load (100,000 kilowatts of load, up to 2 hours). If the load voltage drop still cannot reach the target value of the emergency load gap, the bottom-line guarantee mechanism will be activated. The load management system will send the execution status of the load plan and further control requirements to the dispatching system, which will remotely control the user's incoming circuit breaker and shut down the entire production line to achieve the supply guarantee target.

[0111] S3.1. Establishment of safety threshold selection model.

[0112] The power output of the main power supply line of users in high energy consumption industries will be limited to a certain extent according to the DC side voltage, and will be supplemented by the branch power supply line. The following formula represents this relationship:

[0113] P b (V,t)=P e (V,U dc ,t)+P m (t)

[0114]

[0115] Among them, P b is the main power supply line power, P e is the power of the electrical equipment, P m is the power of the branch power supply line, V is the load, U is the load dc is the output voltage of the electrical equipment, E b From time t I The total power consumption from t to t2 is defined as follows:

[0116]

[0117] Comprehensive analysis shows that as the threshold setting increases, α gradually increases and β gradually decreases. Therefore, in order to ensure maximum safety and comprehensive benefits, the safety threshold should be set at α<A<β.

[0118] When the lower limit of the threshold is set, due to the existence of the internal resistance of the rectifier unit, the voltage at the outlet of the substation will drop to a certain extent. When the upper limit of the threshold is reached, the system alarms and starts the corresponding switch gear adjustment. The judgment adjustment is expressed by the following formula:

[0119] P load (t) = P sub (t)+P ESS (t)

[0120]

[0121] Among them, P load is the load power of the main power supply line, P sub The maximum power provided by the grid, P ESS is the maximum power of the electrical equipment, E load From time t I to the maximum power consumption at t2.

[0122]

[0123] The final upper threshold U max Set the no-load voltage U close to the substation dc0 As m decreases and n increases, the power output ratio provided by the power grid increases. In order to maximize the comprehensive energy efficiency, when the power is sufficient, the power of the electrical equipment should be kept close to a low value.

[0124] S3.2. Safety threshold system.

[0125] Based on the established rectifier unit gear switch safety threshold selection model, it is crucial to build a comprehensive safety threshold system to ensure the stable, efficient and safe operation of the rectifier unit. The system comprehensively considers multiple aspects such as current, voltage, temperature, and the dynamic response of the system to form a multi-dimensional safety monitoring and adjustment framework. The following are the steps and considerations for building such a safety threshold system:

[0126] S3.2.1. Define safety threshold parameters.

[0127] Voltage threshold: Maximum and minimum voltage limits to ensure that the voltage fluctuates within a safe range.

[0128] Current threshold: The maximum allowable current and minimum current level to prevent equipment damage caused by excessive current and system efficiency affected by low current.

[0129] Temperature threshold: The maximum allowable temperature of the rectifier and related power equipment to prevent overheating.

[0130] Dynamic response threshold: safety limit of dynamic performance indicators such as response time and frequency change.

[0131] S3.2.2. Optimization of safety threshold selection model.

[0132] Based on the existing model, the model is further optimized to achieve more accurate safety threshold control. The improved deep learning algorithm is used to predict and adjust the threshold to make it more adaptable to the dynamic changes of the system. The impact of external factors (such as ambient temperature and system load changes) on the safety threshold is considered to ensure the adaptability and flexibility of the threshold setting.

[0133] S3.2.3. Real-time monitoring and adjustment mechanism of safety thresholds.

[0134] Implement high-precision sensors and monitoring equipment to collect data such as voltage, current, temperature, etc. in real time. Develop intelligent control systems that can automatically adjust the working state of the rectifier unit or trigger an alarm mechanism when it detects that the parameters exceed the safety threshold.

[0135] S4. Implement remote regulation and control strategy based on remote load control strategy and safety threshold system.

[0136] S4.1. Hardware design plan.

[0137] The hardware design of the remote on-load voltage regulation rectifier unit gear switch adjustment hardware device is a key technical component of this project. Its design purpose is to achieve remote regulation and optimization of the voltage of electrical equipment. This design mainly includes key components such as hardware framework, remote adjustment switch, BCD decoder, control module, output module and communication module. The specific design ideas are as follows:

[0138] S4.1.1. Framework design objectives.

[0139] Design a stable and reliable hardware framework, including power module, control module, measurement module and output module. Ensure the coordination between the modules to achieve remote load regulation of the voltage of electrical equipment. First, it is necessary to draw the overall framework of the hardware system and clarify the interface relationship and interaction mode between the modules. Among them, the power module needs to provide stable power supply. The control module is the core part of the hardware system and controls the operation of the entire system; the measurement module measures and monitors the output of the system; the output module converts the adjusted voltage into actual current output.

[0140] S4.1.2. Remote adjustment switch design.

[0141] First, select a group of on-load voltage-regulating rectifier units. Through remote adjustment switches, these switches can adjust the voltage level through remote signal transmission. The selection of switches takes into account its reliability, protection level, and easy integration into the entire system. Use reliable solid-state relays as switching elements, use hardware input / output interfaces to communicate with the host computer software, and combine Blynk and other IoT platforms for remote control. Select a Schottky isolation diode as a switching component. Use an optocoupler to receive remote pulse signals, and output logic to the diode after isolation.

[0142] S4.1.3, BCD decoding of gear position signal.

[0143] The signal output by the remote adjustment switch contains information about different gears. These signals are decoded by the BCD (Binary-Coded Decimal) decoder and converted into corresponding digital signals for subsequent control module processing. The design of the BCD decoder needs to consider the stability and reliability of the input signal. A dedicated decoder IC is used to interact with the GPIO interface of the microprocessor to decode the input adjustment signal bit by bit to obtain the specific target voltage gear. CD4511 is used as a BCD decoder, which can convert binary signals into decimal.

[0144] S4.1.4. Control module design.

[0145] By designing a control module, it is responsible for receiving the digital signal after BCD decoding and controlling the output voltage according to the set regulation algorithm. This module needs to consider the accuracy, stability and response speed of voltage regulation. It may be necessary to use PID control algorithm or other advanced control algorithms to ensure stable voltage regulation. In this module, AD7995 is first used as ADC to convert analog signals into digital signals, and then MicroChip's PIC series microcontroller is used to process digital signals, and finally the processed digital signals are converted into analog signals through DAC8571.

[0146] S4.1.5. Output module design.

[0147] By designing an output module, it is responsible for outputting the voltage generated by the control module to the regulated device. This module needs to consider the stability, ripple and overload protection of the output voltage to ensure the safe operation of the electrical equipment. The LM317 voltage regulator is used as the output module. This regulator has protection functions against short circuit and overheating.

[0148] S4.1.6, communication module.

[0149] A communication module is introduced to receive the signal of the remote adjustment switch and pass the digital signal after BCD decoding to the control module. The communication module may choose common communication protocols such as Modbus, CAN, etc. to integrate with other systems. Use MAX485 for RS-485 communication to connect the hardware device and the host computer.

[0150] S4.1.7. Safety and reliability considerations.

[0151] Throughout the design, the safety and reliability of the device are given priority consideration. Appropriate safety mechanisms, such as overload protection and short circuit protection, are used to ensure that electrical equipment is effectively protected under various circumstances.

[0152] S4.1.8. System testing and tuning.

[0153] System testing is performed to verify the stability of the hardware framework and the collaborative work of each module. Adjustments are made based on actual test results to improve the performance and reliability of the entire system. After the hardware is manufactured, a template test is first performed to confirm that each module can work properly. The modules are then combined for system-level testing, including simulation operation testing, extreme condition testing, etc. At the same time, adjustments and optimizations are made for problems that arise during the test to ensure that the final hardware system functions properly and stably.

[0154] S4.2. Gear control method design.

[0155] The load management system is a key component in the power system, responsible for monitoring and managing power loads. Internally, the metering system uses an extension of the DL / T645 protocol to ensure efficient and accurate collection of power data. The DL / T645 protocol is a communication protocol that specifies data formats and transmission rules, providing a standardized interface for the metering system. Through this protocol extension, the load management system can more flexibly adapt to different metering needs and achieve comprehensive monitoring of power usage.

[0156] S4.3. Design of gear position reading method.

[0157] The MR (Modbus RTU) value transmission module plays a key role in the power system, responsible for collecting power data from various devices. Its workflow first involves the BCD code output of the gear information, which provides an important input for the monitoring and control of the power system. The gear information is output in the form of BCD code to ensure the accuracy and reliability of the data. BCD code is a binary encoding form that can effectively represent digital information and is particularly suitable for the accurate description of power system parameters.

[0158] Next, the gear information is parsed by the intelligent joint controller decoding module. As the intelligent center of the system, the intelligent joint controller has a high degree of computing and control capabilities. Its decoding module is responsible for converting BCD codes into understandable power parameters, providing clear and detailed input for the load control terminal (TESAM). By receiving and parsing data from the intelligent joint controller, the load control terminal can perform corresponding operations to achieve precise control of the power system. As the execution endpoint of the power system, TESAM transmits the processed data to the entire system to ensure that the system can effectively maintain a stable operating state when the power demand changes.

[0159] This complete process, from data acquisition by the MR numerical transmission module, to BCD code output of gear information, and then to decoding module processing of the intelligent joint controller, ultimately achieves coordinated operation of the load control terminal and the entire system, providing an efficient and accurate solution for monitoring and dispatching of the power system.

[0160] Steps for designing and implementing the gear position reading method:

[0161] Data collection: First, the MR (Modbus RTU) value transmission module communicates with the device and sends a read request to it to obtain the device's status information, which includes the device's current working status, such as the current gear position.

[0162] / / Define the data storage area

[0163] unsigned char data[DATA_LEN];

[0164] / / Read data from the device

[0165] intlen=modbus_read_registers(ctx,ADDR,NUM_REGS,data);

[0166] if(len==-1){

[0167] fprintf(stderr, "Read failed:%s\n", modbus_strerror(errno));

[0168] return -1;

[0169] }

[0170] Code conversion: The MR value transmission module performs binary encoding on the acquired status information to obtain a binary code. Then, the binary code is encoded in BCD (binary coded decimal) to obtain the BCD code corresponding to each gear position, which will be output as the gear position information.

[0171] Information output: The acquired BCD code is output through the MR module and then sent to the intelligent joint controller.

[0172] Decoding and conversion: The intelligent joint controller receives the gear information encoded in BCD, and then uses the decoding module to perform decoding operations to convert the BCD code into actual gear parameters. At this time, the gear information obtained is essentially the actual gear of the device.

[0173] Information application: After obtaining the actual gear information, the intelligent joint controller can perform precise control based on the gear information, such as adjusting the working status of the equipment.

[0174] S4.4. Design of load sampling method.

[0175] The rectifier unit measurement device plays an important role in the power system, and is responsible for measuring and monitoring the power output of the rectifier unit. First, the measurement device obtains the electrical parameter data of the rectifier unit, including key information such as voltage and current. After being processed and converted by the rectifier unit measurement device, these data are transmitted to the load control terminal (TESAM).

[0176] As an intelligent node of the power system, the load control terminal receives and analyzes the data transmitted by the rectifier unit measurement device. Its functions include data processing and decision making to ensure that the power system is operating in a suitable state. The load control terminal transmits the measurement data of the rectifier unit to the metering system through interaction with the metering system.

[0177] The metering system is responsible for summarizing and recording the electricity and energy data in the entire power system. After receiving the data from the load control terminal, the metering system further analyzes and processes it to generate detailed and accurate power usage reports. These reports not only provide important references for the management of the power system, but also support the operation of the load control system.

[0178] Finally, the rectifier unit measurement device transmits real-time power data to the load management system through the synergy of the load control terminal and the metering system. After receiving this data, the load management system can fully monitor the operation status of the power system and take corresponding measures as needed to ensure the stability and reliability of the power system. The organic connection of this process realizes the efficient transmission and comprehensive utilization of the rectifier unit measurement device data, providing a scientific and reliable basis for the monitoring and management of the power system.

[0179] Data acquisition: In the rectifier unit, the measuring device will capture various working conditions of the equipment, such as voltage, current, etc., and convert this information into electrical parameter data in binary format.

[0180] Data transmission: These electrical parameter data in binary format will be transmitted to the load control terminal via serial communication.

[0181] Data analysis: The negative tube terminal receives the electrical parameter data in binary format, analyzes the data, and converts it into specific power parameter values ​​for subsequent processing and decision-making.

[0182] Data processing: The load-carrying system receives the power parameter value data sent by the load-carrying terminal, collects statistics and analyzes the data through the metering system, and generates reports on power consumption and equipment status.

[0183] Information application: Finally, the report information can be used as a reference for power system operators so that they can understand the use of equipment and formulate relevant strategies and plans as needed.

[0184] S4.5, the overall principle design framework of the rectifier unit control gear adjustment, such as Figure 3 shown.

[0185] The overall schematic diagram of terminal control gear adjustment is an important tool for realizing voltage regulation of electrical equipment in power systems. The schematic diagram mainly includes core components such as remote adjustment switch, BCD decoder, control module and output module. The remote adjustment switch generates corresponding control signals through a set of pre-set switch gears, and these signals are transmitted to the BCD decoder for decoding. The BCD decoder is responsible for converting the switch signal into a digital signal and providing it to the control module. Based on the set adjustment algorithm, the control module generates corresponding control instructions according to the digital signal after BCD decoding to achieve precise voltage regulation. The generated control instructions are transmitted to the power supply system through the output module to adjust the voltage output, which ultimately affects the working state of the terminal electrical equipment. This overall schematic diagram realizes the flexible adjustment of the voltage gear of the terminal equipment in the power system through remote control and digital signal processing, and improves the system's operating flexibility and response speed. In this schematic diagram, the components work together to ensure the accuracy, stability and reliability of voltage regulation, providing effective support for the operation of the power system.

[0186] Downstream of the load management system, the load control terminal (TESAM) plays an important role. As an intelligent terminal, TESAM receives and analyzes data from the metering system, and has the ability to communicate with the intelligent joint controller. As the center of the system, the intelligent joint controller is responsible for coordinating the operations of each terminal and issuing downshift instructions based on the real-time power load conditions. These instructions are transmitted to each terminal through TESAM to achieve dynamic regulation of the power system and ensure the stability and reliability of the system under load fluctuations. This integrated process realizes intelligent supervision and dispatch of the power system through the coordinated work of the load management system, metering system, load control terminal and intelligent joint controller, providing strong support for the efficient operation of power supply. Figure 4 shown.

[0187] S4.6. Access technology solution.

[0188] The access technology solution mainly includes: ① Gear position reading, the main control terminal connects to the communication management machine of the Farad monitoring system through the serial port, and uses the Modbus-rtu protocol to read the on-load voltage regulation gear position data of the rectifier unit. Figure 5 shown.

[0189] ② Gear adjustment: The gear adjustment signal is output by the gear adjustment module, and connected to the on-load voltage regulation downshift interface through the intermediate relay and button switch. During implementation, the double-layer wiring terminal is replaced, and the 1 / 2-level control power supply is disconnected one by one. The intermediate relay and button switch are integrated and installed on an epoxy resin board, which is installed in parallel with the original control panel in the workbench. Figure 6 shown.

[0190] The in-depth analysis of the impact of the rectifier unit gear switch on current and voltage has enriched the theoretical research on load control in high-energy-consuming industries and helped optimize the rectifier unit gear switch adjustment scheme, thereby ensuring the stable operation of users' important electrical appliances.

[0191] An operating boundary condition analysis method for rectifier unit control was established, and detailed explanations were given through specific examples to clarify the specific strategies and steps for load control of users in high-energy-consuming industries, which is conducive to guiding practical operations.

[0192] A safety threshold selection model and a safety threshold system were proposed, which properly handled the relationship between the power of the power supply line and the power of the electrical equipment, ensuring the stable operation of the electrical equipment.

[0193] A remote on-load voltage regulation rectifier unit gear switch adjustment hardware device is designed, taking into account the coordinated work of various parts, realizing remote voltage regulation and improving the working efficiency and safety of the rectifier unit.

[0194] System testing and tuning ensure the performance and reliability of the entire system.

[0195] Through in-depth theoretical research and specific practical plans, a practical and efficient load control solution and equipment is provided for high-energy-consuming industries, which realizes precise remote control of the voltage of electrical equipment, improves the stability and efficiency of the power system, and ensures the safe and stable operation of important electrical appliances.

[0196] Example 2, reference Figure 7 , which is the second embodiment of the present invention, which is different from the previous embodiment in that it provides a high-energy-consuming industry load control safety constraint and remote control system, including: a data acquisition module 100, a remote load control module 200, a safety threshold module 300 and a remote adjustment module 400;

[0197] The data acquisition module 100 is used to collect the operating data of the rectifier unit in real time.

[0198] The remote load control module 200 is used to design a remote load control strategy.

[0199] The safety threshold module 300 is used to construct a safety threshold system according to the collected operation data.

[0200] The remote regulation module 400 is used to implement the remote regulation control strategy according to the remote load regulation strategy and the safety threshold system.

[0201] If the functions are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art or the part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium, including several instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the methods described in each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk, etc., which can store program codes.

[0202] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as an ordered list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by an instruction execution system, device or apparatus (such as a computer-based system, a system including a processor, or other system that can fetch instructions from an instruction execution system, device or apparatus and execute instructions), or in conjunction with such instruction execution systems, devices or apparatuses. For the purposes of this specification, "computer-readable medium" can be any device that can contain, store, communicate, propagate or transmit a program for use by an instruction execution system, device or apparatus, or in conjunction with such instruction execution systems, devices or apparatuses.

[0203] More specific examples of computer-readable media (a non-exhaustive list) include the following: an electrical connection with one or more wires (electronic device), a portable computer disk case (magnetic device), a random access memory (RAM), a read-only memory (ROM), an erasable and programmable read-only memory (EPROM or flash memory), an optical fiber device, and a portable compact disk read-only memory (CDROM). In addition, the computer-readable medium may even be a paper or other suitable medium on which the program is printed, since the program may be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, deciphering or, if necessary, processing in another suitable manner, and then stored in a computer memory.

[0204] It should be understood that the various parts of the present invention can be implemented by hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, a plurality of steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function for a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0205] Example 3, reference Figure 8 , which is the third embodiment of the present invention, and which is different from the first two embodiments in that it is used to verify and illustrate the technical effects adopted in the present invention, so as to verify the real effects of this method.

[0206] Taking the electrolytic aluminum industry as an example, the designed remote adjustment control device can be connected to the existing platform. Yunnan's new power load management system provides strong technical and platform support for the remote control of the rectifier unit switch gear project. The system ensures the efficient operation of the rectifier unit and the realization of remote control through a series of advanced hardware access solutions. Among them, gear reading is a key link. The main control terminal is connected to the Hualite monitoring system communication management machine through the serial port, and the Modbus-rtu protocol is used to read the on-load voltage regulation gear data of the rectifier unit. This technical solution not only ensures the accurate acquisition of data, but also achieves high efficiency and stability of data transmission through the use of advanced communication protocols.

[0207] like Figure 8As shown. In addition, in terms of gear adjustment, the system uses the gear adjustment module to output the adjustment signal, and accesses the on-load voltage regulation downshift interface through the intermediate relay and the button switch. In the specific implementation, the 1 / 2 level control power supply access is disconnected one by one by replacing the double-layer terminal block. The intermediate relay and the button switch are integrated and installed with an epoxy resin board, which is installed in parallel with the original control panel in the workbench. This gear adjustment scheme not only takes into account the feasibility of implementation, but also has been carefully designed in terms of access and operation to ensure the stability and safety of the system.

[0208] In summary, a complete solution for hardware access of the regulating device to the new power load management system in Yunnan has been designed, providing reliable technical support and platform support for remote control of the switch position of the rectifier unit. This comprehensive system integration not only improves the intelligence level of the power system, but also provides sufficient technical guarantee for the realization of project requirements, making the remote control of the rectifier unit more efficient and reliable.

[0209] Finally, through the experiment of remotely adjusting the switch gear of the aluminum plant's rectifier unit, the feasibility of the remote adjustment switch gear hardware was fully verified. In daily operation, the aluminum plant's on-load voltage regulation gear is maintained at 68 gears. After actual adjustment, it is observed that the actual load reduction is about 5,000 kilowatts for each gear reduction. The entire adjustment process takes 1-2 minutes from issuing instructions to completing the gear reduction, and then the next gear can be adjusted. According to the order of "adjusting one gear, stabilizing one gear, and then adjusting the next gear", the gear adjustment is carried out step by step, and the load reduction can be completed within 50 minutes. About 100,000 kW, accounting for 30% of the operating capacity.

[0210] 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 preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A method for safety constraints and remote control of load control in high energy consumption industries, characterized by: include, Collect the operation data of the rectifier unit in real time; Design remote load control strategies; Build a safety threshold system based on the collected operation data; Implement remote regulation and control strategy based on remote load control strategy and safety threshold system.

2. The method for load control safety constraint and remote control in high energy consumption industries according to claim 1, characterized in that: The operating data of the rectifier unit includes voltage, current, power, resistance and temperature.

3. The method for load control safety constraint and remote control in high energy consumption industries as claimed in claim 2, characterized in that: The design of the remote load control strategy includes analyzing the influence of the rectifier unit gear switch on the current and voltage to design the remote load control strategy; The output voltage of the rectifier is calculated as, V out =V in *D uty Among them, V out is the output voltage, V in is the input voltage of the rectifier, D uty is the duty cycle; The output current of the rectifier is calculated as, I out =V in / R load Among them, I out is the output current, R load is the load resistance.

4. The method for load control safety constraint and remote control in high energy consumption industries as claimed in claim 3 is characterized by: The design of remote load control strategy also includes calculating voltage stability and frequency stability; The voltage stability is expressed as, ΔV=|V max -V min | / V nominal Where ΔV is the voltage stability, V max is the maximum voltage, V min is the minimum voltage, V nominal is the rated voltage; The frequency stability is expressed as, Δf=|f max -f min | / f nominal Where Δf is the frequency stability, f max is the maximum frequency, f min is the minimum frequency, f nominal is the rated frequency; Load control is performed through the gear switch adjustment scheme.

5. The method for load control safety constraint and remote control in high energy consumption industries as claimed in claim 4, characterized in that: The safety threshold includes analyzing the operating boundary conditions of the rectifier unit control to set the safety threshold; The power output of the main power supply line of users in high energy consumption industries is limited according to the DC side voltage and supplemented by the branch power supply line, which is expressed as, P b (V,t)=P e (V,U dc ,t)+P m (t) Among them, P b is the main power supply line power, P e is the power of the electrical equipment, P m is the power of the branch power supply line, V is the load, U is the load dc is the output voltage of the electrical equipment, E b From time t I Total power consumption to t2; The safety threshold is set at α<A<β.

6. The method for load control safety constraint and remote control in high energy consumption industries as claimed in claim 5, characterized in that: The safety threshold also includes a lower threshold setting during adjustment. When the upper threshold is reached, an alarm is triggered and the corresponding switch gear adjustment is started. The discrimination adjustment is expressed as: P load (t)=P sub (t)+P ESS (t) Among them, P load is the load power of the main power supply line, P sub The maximum power provided by the grid, P ESS is the maximum power of the electrical equipment, E load From time t I Maximum power consumption to t2; The safety threshold system includes a voltage threshold, a current threshold, a temperature threshold and a dynamic response threshold.

7. The method for load control safety constraint and remote control in high energy consumption industries as claimed in claim 6, characterized in that: The implementation of the remote adjustment control strategy includes designing hardware according to the remote load regulation strategy and the safety threshold system, and performing gear reading and gear adjustment.

8. A system using the method for load control safety constraint and remote control in high energy consumption industries as claimed in any one of claims 1 to 7, characterized in that: It comprises a data acquisition module (100), a remote load control module (200), a safety threshold module (300) and a remote adjustment module (400); The data acquisition module (100) is used to collect the operating data of the rectifier unit in real time; The remote load control module (200) is used to design a remote load control strategy; The safety threshold module (300) is used to construct a safety threshold system according to the collected operation data; The remote adjustment module (400) is used to implement a remote adjustment control strategy according to a remote load regulation strategy and a safety threshold system.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, wherein: When the processor executes the computer program, the steps of the method for safety constraint and remote control of load control in high-energy-consuming industries described in any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method for safety constraint and remote control of load control in high-energy-consuming industries described in any one of claims 1 to 7 are implemented.

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