High-voltage device state data acquisition and monitoring system and method

Abstract

The invention discloses a high-voltage device state data acquisition and monitoring system and method, and belongs to the technical field of power equipment monitoring, the system comprises a data acquisition module, a CPU and a server, a sensor unit of the data acquisition module is connected with a high-voltage device, and the sensor unit comprises a gas sensor and a Hall sensor; the Hall sensor is connected with the voltage acquisition module; the CPU is used for analyzing whether the current is greater than a current preset value, and collecting current data when conditions are met; the voltage acquisition module is connected with the Hall sensor and is used for acquiring voltage data when the current reaches a steady-state current; and the collected gas flow, current and voltage data are transmitted to a server through a gateway. According to the invention, comprehensive monitoring of state data of the high-voltage device is realized, real-time processing of abnormal conditions is realized, meanwhile, data acquisition and control have the advantages of being remote, intelligent and good in universality, more valuable refined data can be provided through intelligent management, and production efficiency and safety are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of power equipment monitoring, and in particular to a high-voltage device state data collection and monitoring system and method. Background Art

[0002] Traditional multifunctional welding machines generally include two functions: plasma argon arc welding and gas shielded welding. When plasma argon arc welding is high-frequency arcing, the welding machine uses a high-frequency high voltage with a frequency of hundreds of thousands of hertz and a voltage of tens of kilovolts (for example, 20,000V) to break through the air gap to form an arc. Taking argon arc welding as an example, the arc starting of argon arc welding adopts a high-voltage breakdown arc starting method. First, a high-frequency voltage is applied between the tungsten needle and the workpiece to break through the argon gas to make it conductive, and then a continuous current is supplied to ensure the stability of the arc. The arc starting methods of argon arc welding machines are divided into contact arc starting and non-contact arc starting. Contact arc starting cannot be used in situations where the weld seam has high requirements. Non-contact arc starting must be used. Non-contact arc starting mostly uses high-frequency oscillation arc starting. High-frequency oscillation arc starting not only has high power consumption, but also high-frequency electricity will cause harm to the human body and interfere with electronic devices and radio. Therefore, it is necessary to collect data and monitor the welding operation status of the high-voltage device with a voltage of up to tens of kilovolts as described above in real time.

[0003] For high-voltage equipment such as argon arc welding, if the output data of the welding machine, i.e., voltage and current parameters, needs to be collected, general hardware equipment is difficult to withstand the arc starting voltage of up to 20,000V, and existing high-voltage welding machines lack a status monitoring system or the status parameter measurement is inconvenient. This makes it difficult for operators to understand the operating status of the equipment in a timely manner, increasing the risk of equipment failure and safety accidents.

[0004] Even if some high-voltage welding machines are equipped with a monitoring system, the monitoring status parameters are often not comprehensive enough. For example, only voltage and current are monitored, while other important parameters such as gas flow are ignored. This one-sided monitoring cannot fully reflect the operating status of the equipment, which may lead to some potential problems being ignored. In addition, with economic development and technological progress, people's demand for automated and intelligent management of high-voltage devices is increasing.

[0005] Existing high-voltage devices lack automation and intelligentization, and do not support remote data collection and control, which limits their application in modern intelligent manufacturing environments. Operators must monitor and adjust on-site, which not only increases labor intensity but also reduces production efficiency.

[0006] Therefore, there is an urgent need to develop a system for data collection and monitoring of the high-voltage welding machine status. Summary of the invention

[0007] The purpose of the present invention is to overcome the problems of the prior art high-voltage welding machine having no state monitoring or inconvenient state parameter measurement, or the monitored state parameters are not comprehensive enough, lacking automation and intelligence, and to provide a high-voltage device state data collection and monitoring system and method.

[0008] In order to achieve the above-mentioned object of the invention, the present invention provides the following technical solutions:

[0009] A high-voltage device status data acquisition and monitoring system, comprising: a data acquisition module, a CPU, and a server, wherein the data acquisition module and the CPU are both communicatively connected to the server in sequence, and the data acquisition module is communicatively connected to the CPU;

[0010] The data acquisition module includes a sensor unit and a voltage acquisition module. The sensor unit is connected to the high-voltage device. The sensor unit includes a gas sensor and a Hall sensor. The gas sensor is used to collect gas flow data of the high-voltage device.

[0011] The Hall sensor is used to collect the current of the high-voltage device, and the CPU is used to analyze whether the current is greater than a preset current value, and when the condition is met, the Hall sensor is used to collect current data;

[0012] The voltage acquisition module is connected to the Hall sensor and is used to acquire voltage data using the voltage acquisition module when the current data acquired by the Hall sensor reaches a steady-state current;

[0013] The data acquisition module transmits the collected gas flow, current and voltage data to the server through the gateway.

[0014] In the above technical solution, the system includes an interconnected data acquisition module, a CPU, and a server. The data acquisition module is the core part of the system, including a sensor unit and a voltage acquisition circuit. The sensor unit in the data acquisition module can obtain the operating status of the device in real time. The sensor unit includes a gas sensor and a Hall sensor. The gas sensor collects gas flow information of the high-voltage device, and the Hall sensor is used to collect the current of the high-voltage device; the voltage acquisition module is used to collect the voltage of the high-voltage device, and transmits the collected gas flow, current, and voltage data to the server through the gateway for monitoring on the server.

[0015] In the technical solution of the present invention, a Hall sensor is used for current detection, electrical isolation is achieved, and accuracy and linearity are improved. The Hall sensor and CPU detect the current and determine the time node for the start of current and voltage acquisition to collect current and voltage data. Through the cooperation of the data acquisition module, CPU and server, comprehensive monitoring of the state data of the high-voltage device is achieved, and abnormal situations are processed in real time. At the same time, data acquisition and control have the advantages of remote, intelligent and good versatility, and can provide more valuable refined data through intelligent management, thereby improving production efficiency and safety. It not only solves the problems of incomplete state monitoring and inaccurate parameter measurement in the prior art, but also realizes remote data acquisition and control, and improves the intelligence level of the system.

[0016] As a preferred solution of the present invention, the data acquisition module also includes a position acquisition unit, which is used to collect the position data of the high-voltage device through GNSS (Global Navigation Satellite System). Through the above technical solution, the data acquisition module of the present invention collects position, gas flow, current data, and voltage data, and the collected data is more comprehensive.

[0017] As a preferred solution of the present invention, the data acquisition module also includes a temperature acquisition unit for collecting temperature information of the high-voltage device. The technical solution of the present application can provide more state parameters by adding a temperature acquisition unit to the data acquisition module and collecting temperature information of the high-voltage device, thereby realizing comprehensive monitoring of the high-voltage device.

[0018] As a preferred solution of the present invention, the voltage acquisition module includes: a power supply and filter circuit, a relay unit, a protection circuit, a signal amplification circuit, an isolation circuit, a signal conditioning circuit, and an A / D conversion circuit which are electrically connected in sequence;

[0019] The filter circuit is used to filter out clutter; the relay unit is used to control the collection of high-voltage data in the voltage; the protection circuit is used to protect circuit components from being damaged by high voltage; the signal amplification circuit is used to amplify weak electrical signals; the isolation circuit is used to perform voltage isolation; the signal conditioning circuit is used to filter, amplify, and convert electrical signals; the A / D conversion circuit is used to convert low-voltage signals into digital signals.

[0020] The voltage acquisition in the prior art usually involves dividing the collected voltage of the high-voltage equipment, collecting voltage data after multiple data reductions, and collecting current data by reducing the data in the same proportion. The parameter acquisition accuracy is insufficient, and inaccurate measurement results may lead to wrong judgments and decisions, thereby affecting industrial production efficiency and even endangering the personal safety of operators. The voltage acquisition module in this technical solution can cut off and divide the pulsed high voltage of 15000V to 20000V, convert it into a measurable analog voltage, and convert the divided analog signal into a digital signal for the CPU to perform parameter analysis. It solves the measurement problem of a voltage of up to 20000V generated by a high-voltage welding machine (such as argon arc welding) when starting an arc, and achieves accurate acquisition of steady-state voltage (10 to 200V) through high-voltage cutting and voltage division technology.

[0021] The voltage acquisition module realizes the accurate acquisition and processing of the voltage signal of the high-voltage device through the combination of power supply and filter circuit, relay unit, protection circuit, signal amplification circuit, isolation circuit, signal conditioning circuit and A / D conversion circuit; the filter circuit can effectively filter out clutter and interference. The relay unit can reliably control the acquisition of high-voltage data.

[0022] The protection circuit can effectively protect the circuit components from high voltage damage through the combination of various protection components. The signal amplification circuit amplifies weak electrical signals through high-precision amplifiers. The isolation circuit achieves electrical isolation through components such as optical couplers. The signal conditioning circuit conditions the signal through components such as filters and amplifiers.

[0023] The A / D conversion circuit converts the low voltage signal into a digital signal through a high-precision A / D converter, which is convenient for subsequent processing and transmission. The voltage acquisition circuit structure of the present application is more perfect and has more comprehensive functions, which can meet the needs of high voltage device status monitoring.

[0024] As a preferred embodiment of the present invention, the filter circuit includes: an AC power supply, a fuse, a thermistor, a varistor, a common mode choke, a capacitor C1, a capacitor C2, a capacitor C3, a capacitor C4, and a capacitor C5. The first port of the fuse is electrically connected to the first port of the AC power supply, the second port of the fuse is electrically connected to the first port of the thermistor, the second port of the thermistor is electrically connected to the first port of the capacitor C1, the first port of the varistor, and the first port of the common mode choke, respectively, the second port of the common mode choke is electrically connected to the second port of the varistor, the second port of the capacitor C1, and the second port of the AC power supply, respectively, the third port of the common mode choke is electrically connected to the first port of the capacitor C2 and the A / D conversion module, the fourth port of the common mode choke is electrically connected to the first port of the capacitor C3 and the A / D conversion module, the second port of the capacitor C2 and the second port of the capacitor C3 are both grounded, the capacitor C4 and the capacitor C5 are connected in parallel and electrically connected to the A / D conversion circuit.

[0025] As a preferred solution of the present invention, the relay unit is a reed relay, which can achieve precise control of high-voltage data acquisition by controlling the on-off of current.

[0026] Due to its fast response speed, it can react quickly when the state of the high-voltage device changes, ensuring the timeliness and accuracy of data collection. In addition, the reed relay has a long service life and can maintain stable performance in long-term operation, reducing maintenance costs.

[0027] As a preferred solution of the present invention, a high-voltage cutoff and voltage-dividing circuit is connected to the voltage acquisition module, which is used to cut off the pulse high voltage and divide it into an analog voltage; the analog signal collected by the voltage acquisition module is converted into a digital signal by an analog-to-digital conversion circuit and transmitted to the CPU for parameter analysis.

[0028] As a preferred solution of the present invention, it also includes an early warning module, which is electrically connected to the server. When it is detected that at least one of the gas flow, current and voltage data exceeds the preset parameter range, the early warning module will issue an alarm and control the data acquisition module to stop data acquisition.

[0029] As a preferred solution of the present invention, the acquisition and monitoring system also includes a client, which is communicatively connected to the server and is used to remotely operate the data acquisition module to acquire data and configure acquisition frequency, current range, and communication protocol.

[0030] Another aspect of the present invention provides a method for collecting and monitoring the status data of a high-voltage device, wherein the high-voltage device status data collection and monitoring system is used to collect and monitor data, and the method comprises the following steps:

[0031] S1. Initializing the acquisition and monitoring system;

[0032] S2, starting the gas sensor to collect gas flow data;

[0033] The Hall sensor is started to collect current, and the CPU is used to analyze whether the current is greater than a preset current value, and current data is collected only when the current condition is met;

[0034] When the collected current data reaches a steady-state current, the voltage collection module is started to collect voltage data;

[0035] S3, preprocessing, framing, and encrypting the collected gas flow, current, and voltage data, and transmitting them to the server through the gateway;

[0036] S4. Monitoring the collected data on the server.

[0037] As a preferred solution of the present invention, the initialization in step S1 includes setting the data acquisition standard, wherein the gas flow acquisition frequency is 0.5 to 3 Hz, and the gas flow range is 0 to 100 LPM;

[0038] Position acquisition frequency 0.005~0.5Hz;

[0039] The temperature collection frequency is 0.5 to 3 Hz, and the temperature alarm threshold is Tc<-20°C or Tc>70°C;

[0040] Current acquisition frequency 50~500Hz, current range 0~800A;

[0041] The voltage acquisition frequency is 50~500Hz, and the voltage range is 0-200V effective steady-state high voltage.

[0042] Compared with the prior art, the present invention has the following beneficial effects:

[0043] 1. A high-voltage device status data acquisition and monitoring system provided by the present invention includes a data acquisition module, a CPU, and a server. The data acquisition module includes a sensor unit and a voltage acquisition module. The sensor unit includes a gas sensor and a Hall sensor. Through these components, multiple parameters such as gas flow, current, and voltage of the high-voltage device can be fully acquired, and analyzed and controlled by the CPU, and finally the data is transmitted to the server for monitoring. This design solves the problems of incomplete status monitoring of high-voltage devices, low measurement accuracy, lack of remote operation and intelligent management in the prior art, and has the advantages of fully monitoring the status of high-voltage devices, improving measurement accuracy, and supporting remote operation and intelligent management.

[0044] 2. The data collection and monitoring system of the present invention can monitor the status and measure parameters of high-voltage devices more comprehensively and accurately, and can accurately locate and process abnormal situations in real time. At the same time, data collection and control have the advantages of remoteness, intelligence, and good versatility, and can provide more valuable and refined data through intelligent management. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 This is a structural block diagram of a high-voltage device status data acquisition and monitoring system according to Embodiment 1 of the present invention;

[0046] Figure 2 A network topology diagram of a high-voltage device status data acquisition and monitoring system according to Embodiment 1 of the present invention;

[0047] Figure 3 This is a collection circuit diagram of the Hall sensor of Example 1 of the present invention;

[0048] Figure 4 for Figure 3 A magnified view of part A;

[0049] Figure 5 for Figure 3 A magnified view of part B;

[0050] Figure 6 This is a structural block diagram of the voltage acquisition module of Example 1;

[0051] Figure 7 for Figure 6 A magnified view of part A;

[0052] Figure 8 for Figure 6 A magnified view of part B;

[0053] Fig. 9 is a structural block diagram of an electric filter circuit according to Embodiment 1 of the present invention;

[0054] Fig.10It is a partial diagram of a high voltage cut-off voltage divider circuit according to Embodiment 1 of the present invention;

[0055] Fig.11 Another partial diagram of the high voltage cut-off voltage divider of Example 1 of the present invention;

[0056] Fig.12 The analog-to-digital conversion circuit diagram of Embodiment 1 of the present invention;

[0057] Fig.13 This is a structural block diagram of a high-voltage device status data acquisition and monitoring system according to Embodiment 4 of the present invention;

[0058] Fig.14 This is a structural block diagram of a high-voltage device status data acquisition and monitoring system according to Embodiment 5 of the present invention;

[0059] Fig.15 This is a flow chart of a method for collecting and monitoring status data of a high-voltage device according to Example 7 of the present invention. DETAILED DESCRIPTION

[0060] The present invention is further described in detail below in conjunction with test examples and specific implementation methods. However, this should not be understood as the scope of the above subject matter of the present invention being limited to the following embodiments, and all technologies realized based on the content of the present invention belong to the scope of the present invention.

[0061] Example 1

[0062] High-voltage devices such as high-voltage welding machines are widely used in industrial production. However, existing high-voltage welding machines have the problem of incomplete status monitoring, which may cause harm to industrial production and personal safety. In addition, with economic development and technological progress, people's demand for automated and intelligent management of high-voltage devices is increasing, and existing high-voltage welding machines also have shortcomings in remote data collection and control.

[0063] In order to solve the above problems, this embodiment provides a high voltage device status data collection and monitoring system, such as Figure 1 , 2As shown, the data acquisition module, CPU, and server, the data acquisition module and the CPU are sequentially connected to the server, and the data acquisition module is connected to the CPU; the data acquisition module includes a sensor unit and a voltage acquisition module, the sensor unit is connected to the high-voltage device, the sensor unit includes a gas sensor and a Hall sensor, the gas sensor is used to collect gas flow data of the high-voltage device; the Hall sensor is used to collect the current of the high-voltage device, the CPU is used to analyze whether the current is greater than the current preset value, and the Hall sensor is used to collect current data when the conditions are met; the voltage acquisition module is connected to the Hall sensor, and when the collected current data reaches the steady-state current, the voltage acquisition module is used to collect voltage data; the data acquisition module transmits the collected gas flow, current, and voltage data to the server through the gateway. In this embodiment, the power supply of the gateway acquisition device is 380VAC, which is consistent with the factory voltage reference, which has limited improvement, and the application compatibility of the hardware equipment in the industrial environment.

[0064] To protect the safety of the entire device, this embodiment uses a Hall sensor to collect the current on the high-voltage device, and uploads the current data to the CPU to determine the time node when the collection starts. The Hall sensor is used to detect the high-voltage current, which can not only perform electrical isolation, but also has high accuracy and good linearity. The collection circuit of the Hall sensor is as follows Figure 3 , 4 , 5, the Hall sensor connects a 4-wire device with Figure 3 At the same time, the voltage conversion circuit of the Hall sensor converts the current signal into a low-voltage signal and gives it to the voltage acquisition module.

[0065] like Figure 6 , 7 As shown in , 8, the voltage acquisition module includes a first-stage operational amplifier, a second-stage operational amplifier, a third-stage operational amplifier, and a fourth-stage operational amplifier. The first-stage operational amplifier is a voltage follower to reduce impedance, the second-stage operational amplifier is a negative feedback network, and the third-stage operational amplifier is an integrator. Specifically, the voltage acquisition module includes a power supply and a filter circuit, a relay unit, a protection circuit, a signal amplification circuit, an isolation circuit, a signal conditioning circuit, and an A / D conversion circuit that are electrically connected in sequence; wherein the filter circuit is used to filter out clutter, eliminate differential-mode interference between input signals and common-mode interference between the input and the circuit ground, thereby improving the acquisition accuracy and reliability of the voltage signal. The wide-range voltage input of 380Vac is compatible with most factory electricity, and fuses, thermistors, varistors, common-mode chokes, and X, Y capacitors are configured for filtering and circuit protection. As shown Fig. 9As shown, the filtering circuit includes: an AC power supply, a fuse, a thermistor, a varistor, a common-mode choke, a capacitor C1, a capacitor C2, a capacitor C3, a capacitor C4, and a capacitor C5. The wide voltage input of 380Vac is compatible with most factory electricity. The first port of the fuse is electrically connected to the first port of the AC power supply, the second port of the fuse is electrically connected to the first port of the thermistor, the second port of the thermistor is electrically connected to the first port of the capacitor C1, the first port of the varistor, and the first port of the common-mode choke respectively, the second port of the common-mode choke is electrically connected to the second port of the varistor, the second port of the capacitor C1, and the second port of the AC power supply respectively, the third port of the common-mode choke is electrically connected to the first port of the capacitor C2 and the A / D conversion module, the fourth port of the common-mode choke is electrically connected to the first port of the capacitor C3 and the A / D conversion module, the second port of the capacitor C2 and the second port of the capacitor C3 are both grounded, the capacitor C4 and the capacitor C5 are connected in parallel, and are electrically connected to the A / D conversion circuit.

[0066] The relay unit is used to control the collection of high-voltage data in the voltage data. Specifically, the relay unit is a reed relay. The protection circuit is used to protect the circuit components from being damaged by high voltage through a combination of multiple protection elements. The signal amplification circuit is used to amplify weak electrical signals through a high-precision amplifier. The isolation circuit is used to divide the 12V voltage into 5V and perform 1:1 voltage isolation through a linear optocoupler, which can effectively isolate the internal signal from the external signal and effectively collect voltage. The signal conditioning circuit is used to filter, amplify, convert and process the electrical signal. The A / D conversion circuit is used to convert the low-voltage signal into a digital signal for subsequent processing and transmission. The reed relay, protection circuit, signal amplification circuit, signal conditioning circuit and A / D conversion circuit use existing circuits that can realize the corresponding functions.

[0067] The voltage acquisition module is connected with a high-voltage cut-off voltage-dividing circuit, which is used to cut off the pulse high voltage of 15000V to 20000V and divide it into analog voltage. The circuit diagram is as follows: Fig.10 , 11 As shown, the high-voltage cutoff voltage divider circuit is connected to the voltage acquisition module, and Voltage_IN and Vin_GND are connected respectively. The analog signal collected by the voltage acquisition module needs to be converted into a digital signal through the analog-to-digital conversion circuit and sent to the CPU through I2C for parameter analysis. The analog-to-digital conversion circuit is as follows Fig.12 .

[0068] This acquisition and monitoring system can monitor the status and measure parameters of high-voltage devices more comprehensively and accurately, and can accurately locate and handle abnormal situations in real time. The high-voltage voltage and current acquisition circuits are highly accurate and safe. At the same time, data acquisition and control have the advantages of remoteness, intelligence, and good versatility, and can provide more valuable and refined data through intelligent management.

[0069] Example 2

[0070] This embodiment provides a high-voltage device status data collection and monitoring system, which is similar to the embodiment 1, except that: the data collection module also includes a position collection unit, such as Figure 2 , which is used to collect the location data of the high-voltage device through GNSS (Global Navigation Satellite System). This design enables the system to track and record its geographical location while monitoring the status of the high-voltage device, providing a more comprehensive monitoring function.

[0071] Position acquisition is achieved by using a GNSS receiver, which receives satellite signals to determine the geographical location of the high-voltage device. The GNSS receiver can include receiving modules for multiple satellite navigation systems such as GPS, GLONASS, and Beidou, thereby ensuring the accuracy and reliability of the location information. In order to improve the accuracy of positioning, a multi-band GNSS receiver can also be used in combination with differential positioning technology.

[0072] Example 3

[0073] This embodiment provides a high-voltage device status data collection and monitoring system, which is similar to Embodiment 1, except that the data collection module further includes a temperature collection unit for collecting temperature information of the high-voltage device.

[0074] The temperature acquisition unit can be implemented in a variety of ways. For example, a variety of temperature sensors such as thermocouples, thermistors, and infrared temperature sensors can be used to collect temperature information. Specifically, thermocouples can output voltage signals by measuring the temperature difference of high-voltage devices, thermistors can output voltage signals by the resistance change caused by temperature changes, and infrared temperature sensors can measure temperature by detecting infrared radiation. Different types of temperature sensors can be selected and configured according to actual application requirements. By adding a temperature acquisition unit to the data acquisition module and collecting the temperature information of the high-voltage device, more status parameters can be provided, thereby achieving comprehensive monitoring of the high-voltage device.

[0075] Example 4

[0076] This embodiment provides a high-voltage device status data collection and monitoring system, which is similar to Embodiment 1, except that the collection and monitoring system further includes an early warning module electrically connected to the server, such as Fig.13As shown in the figure, when the early warning module detects any unsafe state parameters in the gas flow, current and voltage data, the early warning module will issue an alarm and control the data acquisition module to stop data acquisition. Specifically, the alarm is issued through the external buzzer of the gateway. When any unsafe state parameters are detected, the system can automatically cut off the high-voltage power output in time to ensure industrial production and personal safety.

[0077] The setting of the early warning module plays an important role in ensuring safety in the system. When the gas flow, current or voltage data of the high-voltage device is abnormal, the early warning module can determine whether the data is abnormal by setting the corresponding threshold. For example, when the gas flow, current or voltage exceeds the set range, the early warning module will immediately trigger the alarm mechanism. The threshold setting of the early warning module can be adjusted according to the actual application requirements to adapt to different high-voltage devices and working environments.

[0078] The early warning module can be implemented in a variety of ways, such as using a single-chip microcomputer or an embedded system to achieve real-time monitoring and processing of data. In addition, the early warning module communicates with the server through the network and transmits the alarm information to the remote monitoring center to achieve remote monitoring and management. This further improves the safety and reliability of the high-voltage device and meets people's needs for automated and intelligent management of high-voltage devices.

[0079] Example 5

[0080] This embodiment provides a high-voltage device status data collection and monitoring system, similar to Embodiment 1, such as Figure 2 As shown, the difference is that it also includes a client, and the client communicates with the server, such as Fig.14 As shown, it is used for remote operation of collecting and viewing position data, gas flow information, current data, low-pressure data, and high-pressure data, as well as configuring the collection frequency, current range, and communication protocol.

[0081] The client allows users to remotely operate the data acquisition module, collect and view data, and configure the acquisition frequency, current range and communication protocol. As a result, users can monitor and manage high-voltage devices without having to visit the site, greatly improving the convenience and efficiency of operation. The client can be implemented in a variety of ways, such as PC software, mobile applications, etc. The communication between the client and the server can adopt a variety of protocols, such as TCP / IP, HTTP, etc., to ensure the stability and security of data transmission. The interface design of the client should be simple and easy to use, provide a friendly user experience, facilitate user operation, improve the intelligence and automation level of the system, and improve work efficiency and safety.

[0082] Example 6

[0083] This embodiment provides a method for collecting and monitoring the status data of a high-voltage device. The high-voltage device status data collection and monitoring system of Embodiment 1 is used to collect and monitor data. The method includes the following steps:

[0084] S1. Initialize the acquisition and monitoring system;

[0085] S2, start the gas sensor to collect gas flow data;

[0086] Start the Hall sensor to collect current, and use the CPU to analyze whether the current is greater than the preset current value. Only when the current condition is met will the current data be collected;

[0087] When collecting, start the voltage collection module to collect voltage data;

[0088] S3, preprocessing, framing, and encrypting the collected gas flow, current, and voltage data, and transmitting them to the server through the gateway;

[0089] S4. Monitor the collected data on the server.

[0090] Example 7

[0091] This embodiment provides a method for collecting and monitoring the status data of a high-voltage device. The method of Embodiment 6 is used to collect and monitor the status data of a high-voltage device. Fig.15 As shown, this embodiment also collects the location data in Embodiment 2, specifically as follows:

[0092] In step S1, the system is initialized and the data collection standard is set. For position data collection: as long as there is position data, it is uploaded, and the default upload frequency is 60S. For gas flow information collection: as long as there is gas flow data, it is uploaded, and the default upload frequency is 1S. If there is no current and voltage related data when uploading gas flow, the gas flow data is still uploaded, and the current and voltage data are 0 at this time; for current and voltage collection: the sampling frequency is configured according to actual needs, low-range AI / current collection: the CPU reads the voltage value through the analog-to-digital converter ADC, and according to the set current The range is proportionally converted to the current value; that is, the range corresponding to the voltage 0-4V of the low-range AI (that is, the maximum current of a certain welding machine) may be 400A, 800A, ..., 1500A, etc.; for example: the current current range is set to 400A, then 4V corresponds to 400A, 3.2V corresponds to 320A, and 2.5V corresponds to 250A; high-range AI / voltage acquisition: what the CPU reads through ADC is the voltage value, that is, the currently collected voltage; current / voltage collected data: according to the sampling frequency configuration, all values ​​collected within 1s are processed by RMS to obtain the collected current / voltage value.

[0093] In step S2, the logic judgment application scenario is non-pulse acquisition and non-spot welding and the following logic is executed:

[0094] For low-voltage acquisition module scenarios (default sampling frequency 200Hz):

[0095] Current collection logic: When the current is greater than 10A, the Hall sensor collects current data;

[0096] Voltage acquisition logic: When the current is greater than 10A, the voltage acquisition module will collect voltage data (without relay control, the voltage is output to the gateway by default).

[0097] For high voltage acquisition module (with reed relay voltage protection) scenario:

[0098] Normal current / voltage collection (default sampling frequency 200Hz):

[0099] Current collection logic: When the current is greater than 10A, the Hall sensor collects current data;

[0100] Voltage acquisition logic: whether the collected current data reaches the steady-state current. The method for judging the steady-state current is as follows: first collect the continuous (3S) current and pass the current logic (at least the difference between all the sampled current values ​​collected in the last 1s is less than 2A); after judging it as the steady-state current, turn on the reed relay to control the voltage output of the high-voltage acquisition module, and the voltage acquisition module collects the voltage; if the current logic determines that the current is unstable, the reed relay remains closed and the voltage acquisition module does not output the voltage; when the current greater than 10A lasts for less than 3s, it is judged as spot welding. At this time, the reed relay remains closed, no voltage is output to the gateway, and the voltage defaults to 0.

[0101] Through the above judgment logic, the collected gas flow, current and voltage data are preprocessed, framed, encrypted, and transmitted to the server through the gateway. The comprehensive data upload situation is as follows:

[0102] (1) When the current is less than or equal to 10A, there is no current data, no voltage data, and no data upload;

[0103] (2) If the current is greater than 10A and lasts for less than 3s, it is spot welding. The reed relay is closed and the voltage is 0. The maximum current within 3 seconds is uploaded and the voltage is 0V.

[0104] (3) The current is greater than 10A for more than 3s, but is unstable, and the control reed relay is closed. At this time, no voltage is output to the gateway and no data is uploaded;

[0105] (4) The current is greater than 10A for more than 3s and is stable. The reed relay is controlled to conduct. At this time, there is voltage output to the gateway. The current / voltage are uploaded, and the current and voltage are continuously collected and uploaded once every 1s.

[0106] The pulse frequency of pulse sampling is 1-10Hz, and whether it is pulse acquisition is configured by software; only the high-voltage acquisition module has this scenario, and the reed relay is turned on by default; it supports network disconnection and continuous transmission, and it is also necessary to avoid repeated transmission of the same data package within 1s, and upload voltage, current, and gas flow data in one data package at the same time.

[0107] Specifically, the data is uploaded to the server through Ethernet, WIFI Client, and 4G / 5G network, and breakpoint resuming is supported. In the frame format, the frame header: 0x86, the length: the length of one frame outside the frame header, the welding machine address: the monitored welding machine address code, the protocol control code: 0x01 read, 0x00 write..., the data identifier + corresponding data: (0x90 + 1 byte of current data byte) + (0x91 + 1 byte of voltage data byte) + (0x92 + 1 byte of gas flow data) + (0x93 + 1 byte of temperature data byte), the check code: CRC32, the end code: 0x16, the encryption: national encryption SM4. For example:

[0108] Current Raw data {I1, I2…I10}, remove the abnormal data that do not meet the requirements to obtain 10 current sampling data;

[0109] Current Fine data {I} averages 10 sampled data to obtain 1 byte of current data;

[0110] The voltage Raw data {V1, V2…V10} removes the abnormal data that do not meet the requirements to obtain 10 voltage sampling data;

[0111] Voltage Fine data {V} averages 10 sampled data to get 1 byte of voltage data;

[0112] The gas flow Raw data {G1, G2…G10} removes the abnormal data that do not meet the requirements to obtain 10 gas flow sampling data;

[0113] Gas flow Fine data {G} averages 10 sample data to obtain 1 byte of gas flow data;

[0114] The temperature Raw data {T1, T2…T10} removes the abnormal data that do not meet the requirements to obtain 10 temperature sampling data;

[0115] Temperature Fine data {T} averages 10 sampled data to obtain 1 byte of temperature data.

[0116] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A high voltage device status data acquisition and monitoring system, characterized in that: include: A data acquisition module, a CPU, and a server, wherein the data acquisition module and the CPU are both connected to the server in communication, and the data acquisition module is connected to the CPU in communication; The data acquisition module includes a sensor unit and a voltage acquisition module. The sensor unit is connected to the high-voltage device. The sensor unit includes a gas sensor and a Hall sensor. The gas sensor is used to collect gas flow data of the high-voltage device. The Hall sensor is used to collect the current of the high-voltage device, and the CPU is used to analyze whether the current is greater than a preset current value, and when the condition is met, the Hall sensor is used to collect current data; The voltage acquisition module is connected to the Hall sensor, and when the current data collected by the Hall sensor reaches a steady-state current, the voltage acquisition module is used to collect voltage data; The data acquisition module transmits the collected gas flow, current and voltage data to the server through the gateway.

2. A high voltage device status data acquisition and monitoring system according to claim 1, characterized in that: The data collection module also includes a position collection unit for collecting position data of the high-voltage device through GNSS.

3. A high voltage device status data acquisition and monitoring system according to claim 1, characterized in that: The data acquisition module also includes a temperature acquisition unit for acquiring temperature information of the high-voltage device.

4. A high voltage device status data acquisition and monitoring system according to claim 1, characterized in that: The voltage acquisition module includes: a power supply and filter circuit, a relay unit, a protection circuit, a signal amplification circuit, an isolation circuit, a signal conditioning circuit, and an A / D conversion circuit which are electrically connected in sequence; The filter circuit is used to filter out clutter; The relay unit is used to control the collection of medium and high voltage data; The protection circuit is used to protect circuit components from being damaged by high voltage; The signal amplifying circuit is used to amplify weak electrical signals; The isolation circuit is used for voltage isolation; The signal conditioning circuit is used to filter, amplify and convert the electrical signal; The A / D conversion circuit is used to convert the low voltage signal into a digital signal.

5. A high voltage device status data acquisition and monitoring system according to claim 4, characterized in that: The power supply and filter circuit include: an AC power supply, a fuse, a thermistor, a varistor, a common mode choke, a capacitor C1, a capacitor C2, a capacitor C3, a capacitor C4, a capacitor C5, The first port of the fuse is electrically connected to the first port of the AC power supply, and the second port of the fuse is electrically connected to the first port of the thermistor. The second port of the thermistor is electrically connected to the first port of the capacitor C1, the first port of the varistor and the first port of the common mode choke coil respectively. The second port of the common mode choke is electrically connected to the second port of the varistor, the second port of the capacitor C1 and the second port of the AC power supply respectively. The third port of the common mode choke is electrically connected to the first port of the capacitor C2 and the A / D conversion module. The fourth port of the common mode choke is electrically connected to the first port of the capacitor C3 and the A / D conversion module. The second port of the capacitor C2 and the second port of the capacitor C3 are both grounded. The capacitor C4 and the capacitor C5 are connected in parallel and are electrically connected to the A / D conversion circuit.

6. A high voltage device status data acquisition and monitoring system according to claim 4, characterized in that: The relay unit includes a reed relay.

7. A high voltage device status data acquisition and monitoring system according to any one of claims 1 to 6, characterized in that: The voltage acquisition module is connected with a high-voltage cut-off and voltage-dividing circuit for cutting off the pulsed high voltage and dividing it into an analog voltage. The analog signal acquired by the voltage acquisition module is converted into a digital value by an analog-to-digital conversion circuit and transmitted to the CPU for parameter analysis.

8. A high voltage device status data acquisition and monitoring system according to any one of claims 1 to 6, characterized in that: It also includes a client, which is connected to the server for remotely operating the data acquisition module to collect data and configure the acquisition frequency, current range, and communication protocol.

9. A high voltage device status data acquisition and monitoring system according to any one of claims 1 to 6, characterized in that: It also includes an early warning module, which is electrically connected to the server. When at least one of the gas flow, current and voltage data is detected to be beyond the preset parameter range, the early warning module will issue an alarm, and the gateway will control the data acquisition module to stop data acquisition.

10. A method for collecting and monitoring status data of a high voltage device, characterized in that: A high-voltage device status data acquisition and monitoring system according to any one of claims 1 to 9 is used for data acquisition and monitoring, the method comprising the following steps: S1. Initializing the acquisition and monitoring system; S2, starting the gas sensor to collect gas flow data; The Hall sensor is started to collect current, and the CPU is used to analyze whether the current is greater than a preset current value, and current data is collected only when the current condition is met; When the collected current data reaches a steady-state current, the voltage collection module is started to collect voltage data; S3, preprocessing, framing, and encrypting the collected gas flow, current, and voltage data, and transmitting them to the server through the gateway; S4. Monitoring the collected data on the server.

Images