A global real-time multi-directional electric control cabinet monitoring and partition control system

Abstract

A kind of all real-time multi-orientation electric control cabinet monitoring and partition control system, including electric control cabinet, infrared phased array temperature monitoring device, several cooling fans, signal processing module and controller;Electric control cabinet is divided into several areas, several cooling fans are installed in different side walls of electric control cabinet and correspond to several areas one by one;Infrared phased array temperature monitoring device is installed in electric control cabinet to detect the temperature infrared radiation signal of several areas in real time;Signal processing module is connected with infrared phased array temperature monitoring device to filter and amplify the temperature infrared radiation signal of several areas after processing and sent to controller, controller is connected with several cooling fans to calculate and process the information from signal processing module to obtain the temperature information of each area and control the corresponding cooling fan to work, the present application can realize the intelligent control of different area temperature, strengthen the heat dissipation efficiency while reducing energy consumption, effectively reduce the risk of equipment overheating.

Description

Technical Field

[0001] This invention relates to the field of electrical control cabinet monitoring, and in particular to a real-time, multi-directional electrical control cabinet monitoring and zone control system. Background Technology

[0002] An electrical control cabinet is an enclosed device used for centralized control and management of electrical equipment. It is typically made of metal and contains various electrical components such as circuit breakers, relays, contactors, PLCs, frequency converters, and terminal blocks. Electrical control cabinets are commonly used in industrial automation, building electrical systems, and power distribution systems. In electrical systems, they play crucial roles in distributing power, implementing automatic control, protecting electrical equipment, and monitoring equipment status.

[0003] However, in high-power, high-density operating environments, the heat generated by components within the electrical control cabinet increases. Traditional temperature monitoring methods typically employ single-point measurements, which are insufficiently comprehensive and lack real-time response, easily leading to equipment overheating and consequently affecting its performance and lifespan. Furthermore, existing cooling systems often struggle to accurately implement targeted cooling measures for localized overheating areas. Therefore, there is an urgent need to develop a device capable of comprehensively monitoring the temperature inside the electrical control cabinet and achieving precise zoned temperature control, enabling accurate monitoring and adaptive regulation of the cabinet's internal temperature. Summary of the Invention

[0004] The main objective of this invention is to overcome the aforementioned deficiencies in the prior art and propose a real-time, multi-directional electrical control cabinet monitoring and zonal control system. This system can acquire the temperature values ​​of different locations within the electrical control cabinet in real time and from all angles, and then the controller sends different signals to the fans in different areas to achieve precise control of the zoned temperature.

[0005] The present invention adopts the following technical solution:

[0006] A real-time, multi-directional electrical control cabinet monitoring and zone control system includes an electrical control cabinet, an infrared phased array temperature monitoring device, several cooling fans, a signal processing module, and a controller. The electrical control cabinet is divided into several zones, and the cooling fans are installed on different side walls of the electrical control cabinet, corresponding one-to-one with each of the zones. The infrared phased array temperature monitoring device is installed inside the electrical control cabinet to detect the infrared radiation signals of the temperature in the several zones in real time. The signal processing module is connected to the infrared phased array temperature monitoring device to filter and amplify the infrared radiation signals of the temperature in the several zones before sending them to the controller. The controller is connected to the cooling fans to calculate and process the information from the signal processing module to obtain the temperature information of each zone and control the corresponding cooling fans to achieve intelligent temperature control of different zones.

[0007] The infrared phased array temperature monitoring device includes a bracket and several infrared sensor groups. The bracket is installed at the top center of the electrical control cabinet and is provided with several mounting rings to install several infrared sensor groups one by one. Each mounting ring is provided with multiple circumferentially distributed mounting slots. Each infrared sensor group is provided with multiple infrared sensors installed in the corresponding mounting slots and facing different areas.

[0008] The several areas within the electrical control cabinet are distributed along the vertical and horizontal directions; the several mounting rings are coaxially arranged and their diameters gradually increase or decrease, and the several mounting rings are also arranged sequentially in the vertical direction of the electrical control cabinet.

[0009] The distance between the innermost ring of the mounting rings and the top of the electrical control cabinet is less than the distance between the other mounting rings and the top of the electrical control cabinet.

[0010] The number of infrared sensors on the mounting rings gradually increases radially from the inside to the outside; the infrared sensors measure frequencies from 300 GHz to 430 THz and measure infrared wavelengths from 3 μm to 100 μm.

[0011] The electrical control cabinet is divided into six areas in three rows and two columns. Three cooling fans are provided on the two opposite side walls of the electrical control cabinet, which are distributed vertically at intervals to correspond one-to-one with the six areas.

[0012] The controller samples and performs digital-to-analog conversion on the time-domain signal from the signal processing module, then performs a fast Fourier transform on the converted digital signal to convert it into a frequency-domain signal. In the frequency domain, it analyzes the various components of the spectrum to identify signals of different wavelengths, calculates the phase difference between the signals of different wavelengths, and uses the phase difference to calculate the azimuth angle of the region relative to the infrared phased array temperature monitoring device.

[0013]

[0014] in, λ is the phase difference between the infrared sensor corresponding to the region and the adjacent infrared sensor, λ is the wavelength of the infrared radiation emitted by the region, d is the distance between the infrared sensor corresponding to the region and the adjacent infrared sensor, and θ is the azimuth angle of the region relative to the infrared phased array temperature monitoring device.

[0015] The infrared phased array temperature monitoring device calculates the temperature T of each region according to the following Wien displacement formula:

[0016] λ max T = b;

[0017] Where, λmax λ is the infrared wavelength radiated from the region, T is the device surface temperature of the region, and b is Wien's constant.

[0018] It also includes a zoned intelligent cooling control module, which is connected between the controller and the cooling fan. The zoned intelligent cooling control module analyzes the control signals from the controller and intelligently adjusts the angle and wind speed of the cooling fan in the corresponding zone in real time.

[0019] As can be seen from the above description of the present invention, compared with the prior art, the present invention has the following beneficial effects:

[0020] The system of this invention can achieve all-round real-time temperature monitoring through an infrared phased array temperature monitoring device, accurately capturing the infrared radiation of each component in the electrical control cabinet, ensuring a comprehensive understanding of the temperature distribution, and no longer relying on traditional single-point measurement, thereby improving the accuracy and reliability of monitoring.

[0021] The system of this invention divides the entire electrical control cabinet into multiple zones, each equipped with a cooling fan. This system can intelligently adjust the fan speed and direction based on real-time temperature monitoring information, achieving targeted heat dissipation control. This zoned management not only greatly improves heat dissipation efficiency but also effectively reduces energy consumption, prevents overheating hazards, and ensures the safe and stable operation of the electrical control cabinet.

[0022] The modular signal processing mechanism of this invention ensures data filtering and noise reduction, enabling the controller to respond instantly, achieve efficient temperature control, and further enhance the overall performance and energy efficiency of the system. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall system structure of the present invention;

[0024] Figure 2 This is a schematic diagram of the infrared phased array multi-zone temperature measurement device of the present invention.

[0025] Figure 3 This is a schematic diagram illustrating the principle of zoned precise temperature measurement and control in the system of the present invention.

[0026] in:

[0027] 1. Infrared phased array temperature monitoring device; 2. Inner door panel; 3. Outer door panel; 4. Base plate; 5. Cabinet; 6. Cooling fan; 7. Top cover; 8. Micro-break switch mounting plate; 9. Infrared sensor group; 10. Infrared sensor; 11. Bracket; 12. Mounting ring; 13. Mounting slot; 14. Controller; 15. Signal processing unit; 16. Zoned intelligent cooling control module.

[0028] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. Detailed Implementation

[0029] The present invention will be further described below through specific embodiments.

[0030] See Figures 1 to 3 A real-time, multi-directional electrical control cabinet monitoring and zone control system includes an electrical control cabinet, an infrared phased array temperature monitoring device 1, several cooling fans 6, a signal processing module, and a controller 14. The electrical control cabinet is divided into several zones, with the cooling fans 6 installed on different side walls of the cabinet, each corresponding to one of the zones. The infrared phased array temperature monitoring device 1 is installed inside the electrical control cabinet to detect the infrared radiation signals of the temperature in the several zones in real time. The signal processing module is connected to the infrared phased array temperature monitoring device 1 to filter and amplify the infrared radiation signals of the temperature in the several zones before sending them to the controller 14. The controller 14 is connected to the cooling fans 6 to calculate and process the information from the signal processing module to obtain the temperature information of each zone and control the corresponding cooling fans 6 to achieve intelligent temperature control of different zones.

[0031] The electrical control cabinet is a conventional structure, comprising a door panel and a cabinet body 5. The cabinet body 5 has accommodating space and includes a base plate 4, a top cover 7, and a micro-break switch mounting plate 8 to house various electrical components such as circuit breakers, relays, contactors, PLCs, frequency converters, and terminal blocks. The door panel is hinged to the cabinet body 5 to open or close the accommodating space. The door panel may have an inner door panel 2 and an outer door panel 3. The internal division of the electrical control cabinet into several areas is virtual and not physically separated. These areas are distributed vertically and horizontally, forming rows and columns. The number of areas is adjusted according to the size and shape of the electrical control cabinet. For example, in the diagram, the electrical control cabinet is divided into six areas in three rows and two columns. Three vertically spaced cooling fans 6 are installed on each of the two opposite side walls of the cabinet, corresponding to the six areas.

[0032] The infrared phased array temperature monitoring device 1 includes a bracket 11 and several infrared sensor groups 9. The bracket 11 is installed in the top center of the electrical control cabinet and is provided with several mounting rings 12. The mounting rings 12 are ring-shaped, such as circular rings or square rings. The entire bracket 11 is similar to a honeycomb. The bracket 11 is made of aluminum alloy, which is lightweight and easy to manufacture.

[0033] The number of mounting rings 12 corresponds to the number of infrared sensor groups 9, allowing for one-to-one installation of the infrared sensor groups 9. That is, the multi-layer array structure of the infrared sensor groups is arranged on the honeycomb-shaped bracket 11. Each mounting ring 12 has multiple circumferentially distributed mounting slots 13. Multiple infrared sensors 9 are installed in their respective mounting slots 13, facing different areas within the control cabinet. Each infrared sensor 9 is independent and closely arranged.

[0034] Several mounting rings 12 are coaxially arranged with gradually increasing or decreasing diameters; that is, the diameter of the mounting rings 12 gradually increases radially from the inside to the outside and gradually decreases radially from the outside to the inside. The mounting rings 12 are also arranged sequentially in the vertical direction of the electrical control cabinet, i.e., at different heights. After the corresponding infrared sensor 9 is installed on the mounting slot 13 of each mounting ring 12, the entire infrared phased array temperature monitoring device resembles a three-dimensional hemisphere. In the figure, taking three mounting rings 12 and three infrared sensor groups 9 as an example, there are three coaxial mounting rings 12: an outer ring, a middle ring, and an inner ring. The number of infrared sensors 9 in each group decreases progressively inwards. The outer and middle rings are tilted at an angle of 60° relative to the horizontal plane, while the inner ring is tilted at an angle of 32° relative to the horizontal plane.

[0035] Furthermore, in this embodiment, the distance between the innermost ring of the mounting rings 12 and the top of the electrical control cabinet can be set to be smaller than the distance between the other mounting rings 12 and the top of the electrical control cabinet. This arrangement enhances the overall coverage effect of the infrared phased array temperature monitoring device 1.

[0036] The number of infrared sensors on the mounting rings 12 gradually increases radially from the inside to the outside. The infrared sensor 9 measures a frequency range of 300 GHz to 430 THz and an infrared wavelength range of 3 μm to 100 μm. Specifically, the infrared sensor 9 can be an MLX90614 infrared temperature sensor, and each infrared temperature sensor is fitted with a housing for protection. In the figure, a total of 40 MLX90614 infrared temperature sensors are used in multiple infrared sensor groups 9, arranged in a multi-layer array on a honeycomb bracket 11. The signal output lines of each infrared temperature sensor are connected to the subsequent signal processing unit 15 through pre-drilled holes in the bracket 11.

[0037] The signal processing unit 15 has functions such as signal filtering and signal noise reduction. It can perform low-pass filtering and amplification on the temperature infrared radiation signal before sending it to the controller 14. The signal processing unit 15 uses a circuit board with a low-pass filter circuit and an amplification circuit. The low-pass filter is a Butterworth low-pass filter, and the operational amplifier that can be used in the amplification circuit is an LM741.

[0038] The controller 14 of this invention determines the temperature information of different regions based on the varying times required for the infrared radiation signals from different regions to reach the infrared phased array temperature monitoring device 1. Furthermore, it adjusts the rotation speed and direction of the heat sinks in each region according to the different temperature conditions of each zone, achieving intelligent temperature control of different zones, enhancing heat dissipation efficiency while reducing energy consumption, and effectively reducing the risk of equipment overheating.

[0039] When the temperature in one or more areas of the electrical control cabinet rises above a threshold, the infrared radiation emitted by these areas is precisely captured by the infrared temperature sensors on the array. The higher the temperature, the greater the intensity and the shorter the wavelength of the emitted infrared radiation. The temperature T can be calculated using the following Wien displacement formula:

[0040] λ max T = b

[0041] Where, λ max λ is the infrared wavelength of the regional radiation, T is the surface temperature of the device in the region, and b is Wien's constant, b = 0.002897 m·K.

[0042] Specifically, the controller 14 can obtain the phase difference of the temperature in different regions based on the time difference between the arrival of infrared rays in different regions at the infrared phased array temperature monitoring device 1, and further calculate the azimuth angle based on the phase difference. The azimuth angle of the region relative to the infrared phased array temperature monitoring device 1 is calculated using the following formula.

[0043]

[0044] in, λ is the phase difference between the infrared sensor corresponding to the region and the adjacent infrared sensor, λ is the infrared wavelength radiated by the region, d is the distance between the infrared sensor corresponding to the region and the adjacent infrared sensor, and θ is the azimuth angle of the region relative to the infrared phased array temperature monitoring device 1.

[0045] The controller 14 of this invention can be a PLC series controller, wherein the CPU is a Siemens S7-1200 series PLC, which has the advantages of powerful computing function and fast computing speed. The system of this invention may also include a 1920×1080 resolution display, a host equipped with an Intel Core i7 processor, 16GB RAM and 256GB SSD storage space, running the Windows 10 IoT Enterprise operating system, and a keyboard and mouse.

[0046] The system of the present invention is further provided with a partitioned intelligent cooling control module 16 connected between the controller 14 and multiple cooling fans 6, which is used to control the cooling fans 6 according to the signal output by the controller 14. The partitioned intelligent cooling control module 16 uses an STM32F103XC8T6 core development board to build hardware circuits and debugs code in the MDK-ARM development environment to achieve precise adjustment of fan angle and wind speed, thereby achieving precise control of partitioned temperature.

[0047] The working principle of this invention is as follows:

[0048] During actual operation, the infrared phased array temperature monitoring device 1 in the electrical control cabinet acquires infrared radiation from different areas, converts the infrared radiation from optical signals into analog signals, and transmits them to the signal processing unit 15. The signal processing unit 15 then transmits the signal to the controller 14 after smoothing, filtering, and amplification. The controller 14 can easily calculate the wavelength, phase, etc. of the signals from forty independent infrared temperature sensors using an algorithm designed for the phased array. Since the infrared phased array temperature monitoring device 1 is divided into multiple rings (e.g., inner ring, middle ring, outer ring), in order to effectively utilize the analog signals transmitted by all the infrared sensors 9 in the multiple rings, a special pairing method and a multi-channel signal fusion and weighted processing algorithm are used to accurately determine the location of multiple potential high-temperature areas.

[0049] First, each infrared sensor 9 receives aliased signals from different regions, which causes interference due to signal overlap. To solve this problem, the algorithm of the controller 14 first samples the time-domain signal of each sensor, performs digital-to-analog conversion, and then performs a Fast Fourier Transform (FFT) on the resulting digital signal to convert it into a frequency-domain signal.

[0050]

[0051] in, It is a twitch factor. FFT utilizes the periodicity and symmetry of the twitch factor to merge, classify, and organize the data, reducing the number of operations and transforming the digital signal X in the time domain. (n) Divide the sequence into odd-numbered and even-numbered columns based on n, and then use the above formula to decompose the n-point sequence into two elements. By using a butterfly algorithm to calculate the sequence of points, the time-domain analog signal output by the sensor can be quickly converted into a frequency-domain signal, allowing for the identification of signals at different wavelengths. This effectively reduces the number of computations and minimizes signal processing latency.

[0052] In the frequency domain, the various components of the spectrum are analyzed to identify signals of different wavelengths. In this step, the algorithm focuses on demodulating signals of the same wavelength output from adjacent sensors and then calculating the phase difference. For the inner-ring infrared sensors, the algorithm calculates the average phase difference between the two adjacent middle-ring infrared sensors; simultaneously, for the middle-ring infrared sensors, the algorithm also calculates the average phase difference between the two adjacent outer-ring infrared sensors. Furthermore, in signal processing, the controller 14 also incorporates weighted processing and multi-channel signal fusion algorithms. Through the weighted processing algorithm, infrared sensors with high output signal quality are selected, and their wavelengths and phase differences are calculated based on their output signals to initially determine the azimuth corresponding to the wavelengths. The aggregation algorithm then summarizes the signals from each ring, ultimately determining the accurate phase difference corresponding to each wavelength signal. Finally, the azimuth of the wavelength signal is calculated using these phase differences, thereby accurately locating the signal source. The temperature signal corresponding to the wavelength can be calculated using the Wien displacement formula, and the azimuth corresponding to the phase difference can be calculated using the azimuth angle calculation formula, thus determining the real-time temperature of multiple regions.

[0053] Based on the comparison between the real-time temperature and the threshold set for each area, the controller 14 outputs corresponding fan control signals for multiple areas and transmits them to the zone intelligent cooling control module 16. The zone intelligent cooling control module 16 analyzes the received control signals and intelligently adjusts the fan angle and wind speed in real time. The controller 14 displays the multiple area temperature signals and fan speed signals calculated by the controller 14 on the screen in real time. The operator can perform control operations such as switching the electrical control cabinet on and off and adjusting the fans.

[0054] The system of this invention requires only one measuring device to achieve real-time monitoring of the temperature in all directions inside the electrical control cabinet, and can achieve precise control according to the different temperatures of each zone. This significantly improves the heat dissipation effect and reduces energy consumption, effectively reduces the risk of equipment overheating, and extends the service life of the electrical control cabinet, thus having strong application value.

[0055] In this invention, the terms "first," "second," and "third," etc., are used only to distinguish similar objects and are not necessarily used to describe a specific order or sequence, nor should they be construed as indicating or implying relative importance. The use of terms such as "upper," "lower," "left," "right," "front," and "rear" to indicate orientation or positional relationships is based on the orientation or positional relationships shown in the accompanying drawings and is only for the convenience of describing the invention, not to indicate or imply that the device referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation on the scope of protection of this invention. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0056] Furthermore, in the description of this application, unless otherwise stated, "multiple" means two or more. "And / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0057] The above are merely specific embodiments of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial modifications made to the present invention using this concept shall be considered as infringing upon the protection scope of the present invention.

Claims

1. A global real-time multi-directional electric control cabinet monitoring and partition control system, comprising an electric control cabinet, characterized in that, The infrared phased array temperature monitoring device, a plurality of heat dissipation fans, a signal processing module and a controller are further included. The electric control cabinet is divided into a plurality of areas, and the plurality of heat dissipation fans are installed on different side walls of the electric control cabinet and correspond to the plurality of areas one by one. The infrared phased array temperature monitoring device is installed in the electric control cabinet to detect the temperature infrared radiation signals of the plurality of areas in real time. The signal processing module is connected to the infrared phased array temperature monitoring device to filter and amplify the temperature infrared radiation signals of the plurality of areas and then send the signals to the controller. The controller is connected to the plurality of heat dissipation fans to calculate the temperature information of each area from the information from the signal processing module and control the corresponding heat dissipation fans to work to realize intelligent regulation of the temperature of different areas. The infrared phased array temperature monitoring device includes a bracket and a plurality of infrared sensor groups. The bracket is installed in the middle of the top of the electric control cabinet and is provided with a plurality of installation rings to one-by-one install the plurality of infrared sensor groups. Each installation ring is provided with a plurality of circumferentially distributed installation slots. The plurality of infrared sensor groups are provided with a plurality of infrared sensors respectively installed in the corresponding installation slots and facing different areas. The controller samples and digitizes the time domain signals from the signal processing module, and then converts the obtained digital signals into frequency domain signals through fast Fourier transform. Then, in the frequency domain, the components of the frequency spectrum are analyzed to identify signals of different wavelengths. The phase difference of signals of different wavelengths is calculated, and the azimuth angle of the area relative to the infrared phased array temperature monitoring device is calculated based on the phase difference. ； wherein, is the phase difference of the infrared sensor corresponding to the area and the adjacent infrared sensor, λ is the wavelength of the infrared radiation of the area, d is the distance between the infrared sensor corresponding to the area and the adjacent infrared sensor, and θ is the azimuth angle of the area relative to the infrared phased array temperature monitoring device.

2. The global real-time multi-directional electric control cabinet monitoring and partition regulation system according to claim 1, characterized in that: The plurality of areas in the electric control cabinet are distributed along the vertical and horizontal directions. The plurality of installation rings are coaxially arranged and have diameters gradually increasing or decreasing. The plurality of installation rings are also arranged in sequence in the vertical direction of the electric control cabinet.

3. The global real-time multi-orientation electric control cabinet monitoring and partition regulation system of claim 1, wherein: The innermost ring of the plurality of installation rings is closer to the top of the electric control cabinet than the other installation rings.

4. The global real-time multi-directional electric control cabinet monitoring and partition regulation system of claim 1, wherein: The number of infrared sensors on the plurality of installation rings gradually increases from the inside to the outside along the radial direction. The measurement frequency range of the infrared sensors is 300 GHz to 430 THz, and the measurement infrared wavelength range is 3 um to 100 um.

5. The global real-time multi-orientation electric control cabinet monitoring and partition regulation system of claim 1, wherein: The electric control cabinet is divided into six areas arranged in three rows and two columns. The two opposite side walls of the electric control cabinet are respectively provided with three heat dissipation fans distributed along the vertical direction to correspond to the six areas one by one.

6. The global real-time multi-orientation electric control cabinet monitoring and partition regulation system of claim 1, wherein: The infrared phased array temperature monitoring device calculates the temperature T of each area according to the following Wien displacement formula: ； wherein, is the wavelength of the infrared radiation of the region, T is the device surface temperature of the region, and b is the Wien constant.

7. The global real-time multi-orientation electric control cabinet monitoring and partition regulation system according to claim 1, characterized in that: The partition intelligent cooling control module is connected between the controller and the heat dissipation fans. The partition intelligent cooling control module analyzes the control signals from the controller and intelligently adjusts the angle and wind speed of the heat dissipation fans of the corresponding area in real time.

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