Safety relay with valve opening and closing diagnosis function

Abstract

The invention belongs to the technical field of safety relays, and particularly relates to a safety relay with a switch valve diagnosis function, which comprises an MCU (Microprogrammed Control Unit), the input end of the MCU is connected with an optocoupler 1, an optocoupler 2, an optocoupler 3, an optocoupler 4 and a current detection amplifier, and the output end of the MCU is connected with an EEPROM (Electrically Erasable Programmable Read-Only Memory); the optocoupler 1 is connected with a DCS power supply V1, the DCS power supply V1 is also connected with a power supply protection circuit, and the output end of the power supply protection circuit is connected with a K1 relay power supply protection circuit, a K2 relay power supply protection circuit, a K3 relay power supply protection circuit and a K4 relay power supply protection circuit. The execution state of a valve action command and the valve opening and closing state are monitored. Acquisition of valve action data is achieved through digital technical operation, the valve action data are sent to an upper monitoring system in a communication transmission mode in real time, whether the valve needs to be maintained or replaced off line or not is judged in advance, and device shutdown caused by valve faults is avoided.

Description

Technical Field

[0001] The invention relates to the technical field of safety relays, and in particular to a safety relay with a switch valve diagnosis function. Background Art

[0002] Safety relays are composed of several relays and circuits in order to complement each other's abnormal defects and achieve complete relay functions with correct and low false operation. The lower the error and failure value, the higher the safety factor. Therefore, a variety of safety relays need to be designed to protect different levels of machinery. The main goal is to protect machine operators exposed to different levels of danger.

[0003] At present, the work of safety relays is not intelligent enough, so a safety relay with valve switch diagnosis function is designed to seamlessly embed digital diagnosis technology in the quadruple safety relay to monitor the execution status of valve switch action commands and valve switch status. Through digital technology calculation, the valve action data is collected and sent to the upper monitoring system in real time through communication transmission. Summary of the invention

[0004] The object of the present invention is to provide a safety relay with a switch valve diagnosis function to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: a safety relay with a switch valve diagnosis function, comprising: an MCU, wherein an input end of the MCU is connected to an optical coupler 1, an optical coupler 2, an optical coupler 3, an optical coupler 4, and a current detection amplifier, and an output end of the MCU is connected to an EEPROM memory;

[0006] The optical coupler 1 is connected to the DCS power supply V1, and the DCS power supply V1 is also connected to the power supply protection circuit. The output end of the power supply protection circuit is connected to the K1 relay power supply protection circuit, the K2 relay power supply protection circuit, the K3 relay power supply protection circuit, and the K4 relay power supply protection circuit. The K1 relay power supply protection circuit, the K2 relay power supply protection circuit, the K3 relay power supply protection circuit, and the K4 relay power supply protection circuit are connected to the K1 relay coil, the K2 relay coil, the K3 relay coil, and the K4 relay coil, respectively. The 3 relay coils and the K4 relay coils are connected to the K1 common terminal, the K2 common terminal, the K3 common terminal and the K4 common terminal respectively. The peripheries of the K1 common terminal, the K2 common terminal, the K3 common terminal and the K4 common terminal are correspondingly set with the K1 normally open terminal, the K2 normally open terminal, the K3 normally open terminal and the K4 normally open terminal. The K1 common terminal is connected to the K2 common terminal, the fuse and the optocoupler 2. The K1 normally open terminal and the K2 normally open terminal are connected to the K3 common terminal and the K4 common terminal. The K3 normally open terminal and the K4 normally open terminal are connected to the sampling resistor. The sampling resistor is connected to the current detection amplifier and the load. The fuse, the load and the optocoupler 2 are all connected to the load power supply 24V.

[0007] Preferably, the output end of the MCU is also connected to an LED fault light.

[0008] Preferably, the output end of the MCU establishes a connection with the output end of the photoelectric relay fault node, the MCU is bidirectionally electrically connected to the power supply and signal isolation chip, the output end of the photoelectric relay fault node, the power supply and signal isolation chip is connected to the communication and fault output interface, and the input end of the power supply and signal isolation chip is connected to the 24V power supply V2 through the DCDC power conversion circuit.

[0009] Preferably, the signal isolation chip is connected to the MCU via an LDO, and the LDO outputs a 3.3V voltage.

[0010] Preferably, the power supply and signal isolation chip is connected to the communication and fault output interface via a 485 bus.

[0011] Preferably, the optical coupler 3 and the optical coupler 4 receive a valve opening signal and a valve closing signal respectively.

[0012] Preferably, the power supply and signal isolation chip outputs a 5V voltage.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] Digital diagnostic technology is used to monitor the execution status of valve action commands and valve switch status. Through digital technology calculations, valve action data is collected and sent to the upper monitoring system in real time through communication transmission, so as to determine in advance whether the valve needs to be taken offline for maintenance or replacement, and avoid shutdown of the device due to valve failure.

[0015] This solution has the conventional functions of a safety relay control module (implementing isolation between input and output signals, providing one normally open (NO) contact, using redundancy technology of two-in-two parallel connection followed by series connection and contact welding protection technology, output contact capacity of 5A, unique FDW design, compatible with dry and wet node connections without the need for additional external terminals.), and also adds a sampling resistor to the output channel (collecting load loop current), collects the corresponding switch valve action command and the switch status signal when the switch valve is in action, and sends the collected information to the MCU module, determines the relevant time of the corresponding action through signal processing, and realizes the diagnosis function of the health status of the corresponding switch valve. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a system logic block diagram of the present invention;

[0017] Figure 2 is a circuit schematic diagram of the present invention;

[0018] Figure 3 A circuit diagram of a sampling relay power supply in a monitoring circuit of the present invention;

[0019] Figure 4 A circuit diagram for sampling a load power supply voltage in a monitoring loop of the present invention;

[0020] Figure 5 A circuit diagram of a monitoring circuit sampling a current in a load circuit of the present invention;

[0021] Figure 6 This is the circuit diagram of the monitoring loop of the present invention. DETAILED DESCRIPTION

[0022] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0023] In the description of the present invention, it is necessary to understand that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0024] Embodiment 1:

[0025] See also Figure 1-5 The present invention provides a technical solution: a safety relay with a valve switch diagnostic function, comprising: an MCU, wherein the input end of the MCU is connected to an optocoupler 1, an optocoupler 2, an optocoupler 3, an optocoupler 4, and a current detection amplifier, the output end of the MCU is connected to an EEPROM memory, the output end of the MCU is also connected to an LED fault light, and the optocoupler 3 and the optocoupler 4 receive a valve opening signal and a valve closing signal respectively;

[0026] The optical coupler 1 is connected to the DCS power supply V1, and the DCS power supply V1 is also connected to the power supply protection circuit. The output end of the power supply protection circuit is connected to the K1 relay power supply protection circuit, the K2 relay power supply protection circuit, the K3 relay power supply protection circuit, and the K4 relay power supply protection circuit. The K1 relay power supply protection circuit, the K2 relay power supply protection circuit, the K3 relay power supply protection circuit, and the K4 relay power supply protection circuit are connected to the K1 relay coil, the K2 relay coil, the K3 relay coil, and the K4 relay coil, respectively. The 3 relay coils and the K4 relay coils are connected to the K1 common terminal, the K2 common terminal, the K3 common terminal and the K4 common terminal respectively. The peripheries of the K1 common terminal, the K2 common terminal, the K3 common terminal and the K4 common terminal are correspondingly set with the K1 normally open terminal, the K2 normally open terminal, the K3 normally open terminal and the K4 normally open terminal. The K1 common terminal is connected to the K2 common terminal, the fuse and the optocoupler 2. The K1 normally open terminal and the K2 normally open terminal are connected to the K3 common terminal and the K4 common terminal. The K3 normally open terminal and the K4 normally open terminal are connected to the sampling resistor. The sampling resistor is connected to the current detection amplifier and the load. The fuse, the load and the optocoupler 2 are all connected to the load power supply 24V.

[0027] The output end of the MCU is connected to the output end of the photoelectric relay fault node, the MCU is bidirectionally electrically connected to the power supply and signal isolation chip, the output end of the photoelectric relay fault node, the power supply and signal isolation chip is connected to the communication and fault output interface, the input end of the power supply and signal isolation chip is connected to the 24V power supply V2 through the DCDC power conversion circuit, the signal isolation chip is connected to the MCU through the LDO, and the LDO outputs a 3.3V voltage. The power supply and signal isolation chip is connected to the communication and fault output interface through the 485 bus, and the power supply and signal isolation chip outputs a 5V voltage.

[0028] like Figure 2 As shown, the circuit diagram is Figure 1 System logic box Figure 1 One-to-one correspondence (due to Figure 2 The size is limited, and the details are difficult to show. Figure 1 You can learn more about the content of the plan).

[0029] like Figure 3 As shown in the figure, it is a circuit for sampling the power supply of the relay in the monitoring circuit. In this circuit, the power supply S IV+ (S IV-) signal is converted into the power supply signal by the optocoupler and then enters the MCU for signal processing. This part of the circuit is isolated from the safety relay by the optocoupler. When the 3VCC power supply circuit fails, it does not affect the output of the safety relay circuit. The S IV+ (S IV-) circuit fails, and does not affect the 3VCC circuit.

[0030] like Figure 4 As shown in the figure, it is a circuit for sampling the load power supply voltage in the monitoring loop. In this circuit, the load power supply 24V+(24V-) signal is converted into the power supply signal by the optocoupler and then enters the MCU for signal processing. This part of the circuit is isolated from the safety relay by the optocoupler. When the 3VCC power supply circuit fails, it does not affect the output of the safety relay circuit. The 24V+(24V-) circuit fails, and does not affect the 3VCC circuit. Therefore, the monitoring loop is safety-independent.

[0031] like Figure 5 As shown in the figure, it is a circuit for monitoring the current in the sampling load loop. The current detection amplifier SGM8193A0 collects the small voltage difference between the two ends of the sampling resistor. The corresponding voltage value is output to the MCU for AD conversion, and the program processes it into the corresponding current value. According to the circuit requirements, the power ground of SGM8193A0 and MCU is connected to 24v-.

[0032] If the 4.5 pin of SGM8193A0 is short-circuited, the sampling resistor is short-circuited, and the safety relay outputs normally. It is not affected. At this time, AD1 outputs 0, which does not affect the MCU circuit.

[0033] If the 4.5 pin of SGM8193A0 is disconnected, the sampling resistor is not affected, and the safety relay outputs normally. At this time, AD1 outputs 0, which does not affect the MCU circuit.

[0034] like Figure 6 The monitoring circuit is shown in the figure. The monitoring circuit is powered by a separate power supply. The input uses TVS and self-recovery fuses for overvoltage and overcurrent protection and electromagnetic compatibility. SGM61430 is used to output 5V to power the 485 chip. After the isolation chip IS3643LW, the output is isolated 5V, and then through the LDO to output 3.3V. It powers the MCU, storage chip, optocoupler, photoelectric relay, and indicator light.

[0035] Overall function: when MCU works normally, it collects the current value of the load circuit, the switch valve action command signal and the switch status signal, sets the normal current range and calculates the valve action time, and transmits the relevant valve status information to the monitoring system through MODBUS communication for monitoring and analysis.

[0036] In the safety relay power supply circuit, a 1A slow-blow fuse, TVS tube and self-recovery fuse are designed at the input end, as well as an over-current and over-voltage protection design.

[0037] This solution has the conventional functions of a safety relay control module (implementing isolation between input and output signals, providing one normally open (NO) contact, using redundancy technology of two-in-two parallel connection followed by series connection and contact welding protection technology, output contact capacity of 5A, unique FDW design, compatible with dry and wet node connections without the need for additional external terminals.), and also adds a sampling resistor to the output channel (collecting load loop current), collects the corresponding switch valve action command and the switch status signal when the switch valve is in action, and sends the collected information to the MCU module, determines the relevant time of the corresponding action through signal processing, and realizes the diagnosis function of the health status of the corresponding switch valve.

[0038] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention; therefore, no matter from which point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is limited by the attached claims rather than the above description. Therefore, it is intended to include all changes within the meaning and scope of the equivalent elements of the claims in the present invention, and any figure marks in the claims should not be regarded as limiting the claims involved.

[0039] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A safety relay with a switch valve diagnostic function, characterized in that: It includes: an MCU, wherein an input end of the MCU is connected to an optocoupler 1, an optocoupler 2, an optocoupler 3, an optocoupler 4, and a current detection amplifier, and an output end of the MCU is connected to an EEPROM memory; The optical coupler 1 is connected to the DCS power supply V1, and the DCS power supply V1 is also connected to the power supply protection circuit. The output end of the power supply protection circuit is connected to the K1 relay power supply protection circuit, the K2 relay power supply protection circuit, the K3 relay power supply protection circuit, and the K4 relay power supply protection circuit. The K1 relay power supply protection circuit, the K2 relay power supply protection circuit, the K3 relay power supply protection circuit, and the K4 relay power supply protection circuit are connected to the K1 relay coil, the K2 relay coil, the K3 relay coil, and the K4 relay coil, respectively. The 3 relay coils and the K4 relay coils are connected to the K1 common terminal, the K2 common terminal, the K3 common terminal and the K4 common terminal respectively. The peripheries of the K1 common terminal, the K2 common terminal, the K3 common terminal and the K4 common terminal are correspondingly set with the K1 normally open terminal, the K2 normally open terminal, the K3 normally open terminal and the K4 normally open terminal. The K1 common terminal is connected to the K2 common terminal, the fuse and the optocoupler 2. The K1 normally open terminal and the K2 normally open terminal are connected to the K3 common terminal and the K4 common terminal. The K3 normally open terminal and the K4 normally open terminal are connected to the sampling resistor. The sampling resistor is connected to the current detection amplifier and the load. The fuse, the load and the optocoupler 2 are all connected to the load power supply 24V.

2. A safety relay with a switch valve diagnostic function according to claim 1, characterized in that: The output end of the MCU is also connected to an LED fault light.

3. The safety relay with a switch valve diagnostic function according to claim 1, characterized in that: The output end of the MCU establishes a connection with the output end of the photoelectric relay fault node, the MCU is bidirectionally electrically connected to the power supply and signal isolation chip, the output end of the photoelectric relay fault node, the power supply and signal isolation chip is connected to the communication and fault output interface, and the input end of the power supply and signal isolation chip is connected to the 24V power supply V2 through the DCDC power conversion circuit.

4. A safety relay with a switch valve diagnostic function according to claim 3, characterized in that: The signal isolation chip is connected to the MCU via an LDO, and the LDO outputs a 3.3V voltage.

5. A safety relay with a switch valve diagnostic function according to claim 3 or 4, characterized in that: The power supply and signal isolation chip is connected to the communication and fault output interface via a 485 bus.

6. The safety relay with a switch valve diagnostic function according to claim 1, characterized in that: The optical coupler 3 and the optical coupler 4 receive a valve opening signal and a valve closing signal respectively.

7. The safety relay with a switch valve diagnosis function according to claim 4, characterized in that: The power supply and signal isolation chip outputs a 5V voltage.

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