Energy storage type multifunctional control device and control system

Abstract

The invention provides an energy storage type multifunctional control device and a control system, and aims to solve the problems that in an automatic valve control technology, power supply driving is depended, and a valve body cannot realize reliable operation in an emergency, a power supply circuit comprises a hybrid energy storage unit, and the hybrid energy storage unit comprises at least two groups of parallel super capacitors and a standby battery unit; the super capacitors are formed by connecting a plurality of super capacitors in parallel to form super capacitor banks, each super capacitor bank and the standby battery unit form an independent power supply path, and when it is judged that the external power supply loses power, the power supply switching unit is preferentially switched to any super capacitor bank according to a preset priority; the control unit drives the motor to act according to a preset instruction to achieve operation of the valve body at a designated position under the condition that an external power source loses power. And when the super-capacitor banks are not started or the valve body is not completely driven to a specified position or the voltage of each super-capacitor is lower than a nominal value, the standby battery unit supplies power. The invention is mainly used in the field of automatic control of pipeline valves.

Description

Technical Field

[0001] The present invention relates to a pipeline control device, and particularly to an energy storage type multi-functional control device and a control system. Background Art

[0002] In the management of pipeline systems such as oil, chemical industry, and ships, the use of automated valve control devices such as pneumatic, electro-hydraulic, and gas-liquid is already a technological trend. Emergency valve cut-off under high-risk working conditions is a core technical index of automated valve control devices. Usually, high-risk working conditions must consider the situation when the system loses external power, but traditional automated valve control devices must rely on electricity for driving.

[0003] Conventional solutions usually adopt the method of redundant backup power supply to solve the problem. However, in pipeline systems, the number of valves is large, the demand for redundant backup power is large, and the maintenance cost is high. Moreover, the oil and chemical industries are not suitable for frequent disassembly and assembly of redundant backup power supplies. Summary of the Invention

[0004] The present application proposes an energy storage type multi-functional control device, aiming to solve the problem that in the automated valve control technology, it relies on power supply for driving and the valve body cannot be operated reliably in case of emergency.

[0005] Its technical solution is that it includes an electric actuator and an electric control system; The electric control system includes a power supply circuit, a control circuit, and a detection circuit; The power supply circuit supplies power to the control unit, the detection circuit, and the motor; The control circuit controls the motor to act through a motor drive circuit to realize the action of the valve body; The detection circuit includes a part for detecting power supply information; The power supply circuit includes a hybrid energy storage unit, and the hybrid energy storage unit includes at least two groups of parallel supercapacitors and at least one group of backup battery units; each group of supercapacitors is composed of multiple supercapacitors connected in parallel to form a supercapacitor group, and each supercapacitor group and the backup battery unit form an independent power supply path for the electric control system and the motor; It also includes a power supply switching unit for switching the power supply circuit. When it is judged that the external power supply is out of power through the external power supply voltage threshold condition, the power supply switching unit preferentially switches to any supercapacitor group according to a predetermined priority, and the control unit drives the motor to act according to a preset instruction to realize the specified position operation of the valve body in the case of external power supply loss; The switching between multiple groups of supercapacitor groups is switched between groups according to a dynamic distribution algorithm, and the inter-group switching delay is less than 500 μs; When each super capacitor bank is not started or not fully driven to the specified position, or when the voltage of each super capacitor is lower than the nominal value, the power supply switching unit switches to the backup battery unit for power supply.

[0006] In the above or some embodiments, the electric actuator includes a motor, a transmission device, and a power output device. The motor outputs the execution action to the power transmission device through the transmission device, and the power transmission device is linked with the valve body to realize the action of the valve body.

[0007] In the above or some embodiments, the power supply circuit includes an external power supply, the hybrid energy storage unit, a power supply switching unit, a power management unit, and a charging management unit; output paths of each super capacitor bank and the backup battery unit respectively form power branches, and each power branch is provided with an independent MOSFET switching switch and reverse current protection to form a MOSFET switching matrix. The main controller of the control circuit controls the on / off of each MOSFET switching switch to form the power supply switching unit.

[0008] In the above or some embodiments, a remote communication unit is further included. The remote communication unit includes a wired communication unit and a wireless communication unit; the wired communication unit uses an RS485 communication module to realize communication connection with the remote DCS system; the wireless communication unit uses a 4G and / or 5G communication module to realize communication connection with the remote DCS system.

[0009] In the above or some embodiments, the charging management unit is used to charge the backup battery unit and each super capacitor bank; the charging management unit is provided with a voltage detection circuit for detecting the voltage across the backup battery unit and the terminal voltage of each super capacitor bank. When the detected voltage is lower than the preset value, charging is started until the preset voltage value is reached.

[0010] In the above or some embodiments, each energy storage type multi-functional control device is communicatively connected through the remote communication unit. Each energy storage type multi-functional control device is preset with an interlock instruction set for driving the valve body action, and specifies that a single or multiple energy storage type multi-functional control devices realize the control of their respective corresponding or specified valve bodies according to the interlock instruction set.

[0011] In the above or some embodiments, the energy storage type multi-functional control device is also communicatively connected with the remote DCS system through the remote communication unit and receives control instructions.

[0012] In the above or some embodiments, the electric control system further includes an information acquisition circuit, including a valve body position information, a system power supply information, and a temperature information acquisition circuit.

[0013] When the external power supply fails, the present invention can achieve the valve body operation in an emergency state through a backup power supply and other associated control devices or remote control systems. The backup power supply located in the main body uses multiple supercapacitor banks and battery packs to supply power to the system. Due to the characteristics of supercapacitors, when the supercapacitors are enabled for power supply, a rapid operation response of 0 - 200 ms for the valve body can be achieved. Even in the case of the failure of the supercapacitor bank, the system can still be powered by the backup battery unit. When an emergency occurs in an adjacent control device, a reminder for the associated control device can be achieved through the remote communication unit, and the valve body operation in an emergency can be triggered. Multiple control devices can control the actions of the valve bodies of the interlocking objects through control instructions issued by the remote DCS system or relying on the instruction sets stored in their respective memories. The interlocking control objects can be triggered according to the event judgment results to form the interlocking operations of multiple valve bodies, so as to ensure the overall safety of the pipeline system and the reliability of the valve body operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a schematic structural diagram of the present invention.

[0015] Figure 2 It is a schematic diagram of the principle of the control system of the present invention.

[0016] Figure 3 It is the judgment logic of the power supply circuit.

[0017] Figure 4 It is the power supply circuit diagram of the hybrid energy storage unit in an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0018] To make the objectives, features, and advantages of the present invention more obvious and understandable, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the embodiments described below are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0019] The energy storage type multi-functional control device includes an electric actuator and an electric control system. The electric actuator relies on electricity to achieve actions, and then drives the valve body to act, realizing the start, closing, or opening degree control of the valve body. The electric control system is used to provide control signals and power support to achieve control.

[0020] Such as Figure 1In the above or some embodiments, the electric actuator includes a motor, a transmission device, and a power output device, and the motor outputs the execution action to the power transmission device through the transmission device. It also includes a housing, and the motor is fixed in the middle position of the housing. The middle and upper parts of the housing are provided with spaces for installing circuit components of the electric control system, such as a printed circuit board and a supercapacitor group. The transmission device is fixedly installed at the output shaft end of the motor, and the transmission device adopts the applicant's planetary gear reduction device, as recorded in patent documents such as application number CN201820136140.5, application number: CN201820136776.X, and application number: CN201820136118.0. The lower end of the transmission device is connected to the rotating control shaft of the valve body through the power output shaft to realize the motion control of the valve body.

[0021] Of course, in order to provide auxiliary functions, such as meeting the use in flammable and explosive environments, the motor can be an explosion-proof motor, and the housing can be designed and installed according to the explosion-proof grade requirements, such as setting up an explosion-proof cable isolation chamber, wiring terminal isolation, etc. In order to display the system operating conditions, a display screen can be set outside the housing to display the current valve body position information, current, voltage information, and internal temperature information.

[0022] The electric control system includes a power supply circuit, a control circuit, and a detection circuit. The power supply circuit supplies power to the control unit, the detection circuit, and the motor; the control circuit controls the motor to move through the motor drive circuit to realize the movement of the valve body; the detection circuit includes a circuit for detecting power supply information.

[0023] The power supply circuit includes an external power supply, a hybrid energy storage unit, a power switching unit, a power management unit, and a charging management unit. The external power supply, each of the supercapacitor groups, and the output paths of the backup battery unit form power supply branches. In the external power supply branch, the external power supply relies on the mains (220V) or wind and solar energy systems to power the internal system, which can solve the problem of energy acquisition in an environment without mains supply or with good solar and wind energy resources.

[0024] To prevent the electric actuator from being inoperable when the external power supply fails, a hybrid energy storage unit is adopted inside this device. In the above or some embodiments, the hybrid energy storage unit includes two groups of parallel-connected supercapacitors and at least one group of backup battery units; each group of the supercapacitors is composed of multiple supercapacitors connected in parallel to form a supercapacitor bank, and the supercapacitor bank can meet the requirement of short-time high-power output in case of external power supply failure to realize the emergency operation of the valve body. Each supercapacitor bank and the backup battery unit form an independent power supply path for the electric control system and the motor; of course, it also includes a power supply switching unit for switching the power supply circuit. When judging that the external power supply has lost power through the external power supply voltage threshold condition, the power supply switching unit preferentially switches to any one of the supercapacitor banks according to a predetermined priority. The supercapacitor banks are switched between groups according to a dynamic distribution algorithm. When the supply supercapacitor bank is lower than 60% of the nominal voltage, it switches to another supercapacitor bank for power supply, and the inter-group switching delay is less than 500 μs.

[0025] When each supercapacitor bank is not started or has not fully driven the valve body to the specified position or the voltage of each supercapacitor is lower than the nominal value, the power supply switching unit switches to the backup battery unit for power supply. Whether the valve body is driven to the specified position is measured and fed back to the control unit by the encoder. The control unit drives the motor to act according to a preset command to realize the specified position operation of the valve body in case of external power supply failure. In the above or some embodiments, the control unit is communicatively connected to the remote DCS system through a remote communication unit, including a wired communication unit and a wireless communication unit. The wired communication unit realizes the communication connection with the remote DCS system by using an RS485 communication module; the wireless communication unit is realized by using a 4G and / or 5G communication module, and the RS485 communication module can adopt a TD301D485H-A transceiver module.

[0026] In the above or some embodiments, each power branch is provided with an independent MOSFET switching switch and reverse current protection to form a MOSFET switching matrix, and the main controller of the control circuit controls the on / off of each MOSFET switching switch to form the power supply switching unit.

[0027] In the above or some embodiments, the charging management unit is used to charge the backup battery unit and each supercapacitor bank; the charging management unit is provided with a voltage detection circuit for detecting the voltage across the backup battery unit and the voltage across each supercapacitor bank. When the detected voltage is lower than the preset value, charging is started until the preset voltage value is reached. In a specific embodiment, the TPS2412 chip can be used for the switching control of the redundant power supply. Each power supply branch outputs to the power bus. Each TPS2412 chip detects the voltage at the input and output ends of each power supply branch, and the MOSFET at each power supply branch is turned on through an internal comparator to realize power supply. Of course, the switching between supercapacitor banks can also be realized by the LTC4416 chip. Through the control signals input at the E1 and E2 terminals, it is determined that the MOSFETs of Group1 and Group2 are turned on to realize power supply.

[0028] In the management of pipeline systems such as oil, chemical, and shipbuilding, the action of the valve body often requires an interlock reaction. When an emergency occurs, multiple valve bodies may need to be operated. At this time, the list of valve bodies with interlock reactions triggered by events can be set to determine information such as the timing of the operation of each valve body. When the determined event occurs, the operation instruction set of the valve body under the emergency can be triggered automatically. To meet the above implementation scheme, in the above or some embodiments, each of the energy storage type multifunctional control devices is communicatively connected through the remote communication unit. Each of the energy storage type multifunctional control devices is preset with an interlock instruction set for driving the valve body to act, and specifies that a single or multiple energy storage type multifunctional control devices realize the control of their corresponding or designated valve bodies according to the interlock instruction set. The energy storage type multifunctional control device is also communicatively connected to the remote DCS system through the remote communication unit and receives control instructions. Of course, the remote communication unit also collects information including valve body position information, system power supply information, temperature information, etc. through an information acquisition circuit and transmits it to the remote DCS system.

[0029] When the external power supply fails in the present invention, the valve body operation in the emergency state can be realized through the backup power supply and other associated control devices or remote control systems. The backup power supply located in the main body adopts multiple supercapacitor banks and a battery bank to realize system power supply; due to the characteristics of the supercapacitor, when the supercapacitor is enabled for power supply, a rapid operation response of 0 - 200 ms to the valve body can be achieved. Even in the case of the failure of the supercapacitor bank, the system can still be powered by the backup battery unit. When an emergency occurs in an adjacent control device, the associated control device can be reminded through the remote communication unit, and the valve body operation in the emergency can be triggered. Multiple control devices can control the actions of the valve bodies of the interlock objects through the control instructions issued by the remote DCS system or relying on the instruction sets stored in their respective memories. The interlock control objects can be triggered according to the event judgment results to form the interlock operation of multiple valve bodies, so as to ensure the overall safety of the pipeline system and the reliability of the valve body operation.

Claims

1. Energy storage type multi-functional control device, comprising an electric actuator and an electric control system; The electric control system includes a power supply circuit, a control circuit, and a detection circuit; The power supply circuit supplies power to the control unit, the detection circuit, and the motor; The control circuit controls the motor to act through a motor drive circuit to realize the valve body action; The detection circuit, the detection circuit includes means for detecting power supply information; Characterized in that, The power supply circuit includes a hybrid energy storage unit, the hybrid energy storage unit includes at least two groups of parallel supercapacitors, and at least one group of backup battery units; each group of the supercapacitors is formed by parallel connection of a plurality of supercapacitors to form a supercapacitor bank, and each of the supercapacitor banks and the backup battery unit form independent power supply paths for the electric control system and the motor; It further includes a power supply switching unit for switching the power supply circuit. When it is judged that the external power supply is powered off through the external power supply voltage threshold condition, the power supply switching unit preferentially switches to any one of the supercapacitor banks according to a predetermined priority, and the control unit drives the motor to act according to a preset instruction to realize the specified position operation of the valve body under the condition of external power supply loss; Inter-group switching is carried out among multiple groups of supercapacitor banks according to a dynamic distribution algorithm, and the inter-group switching delay is less than 500 μs; When each group of supercapacitor banks is not started or has not completely driven the valve body to the specified position or the voltage of each supercapacitor is lower than the nominal value, the power supply switching unit switches to the backup battery unit for power supply.

2. The energy storage type multi-functional control device according to claim 1, characterized in that, The electric actuator includes a motor, a transmission device, and a power output device. The motor outputs an execution action to the power transmission device through the transmission device, and the power transmission device is linked with the valve body to realize the action of the valve body.

3. The energy storage type multi-functional control device according to claim 2, characterized in that, The power supply circuit includes the external power supply, the hybrid energy storage unit, the power supply switching unit, the power management unit, and the charging management unit; the output paths of the external power supply, each supercapacitor bank, and the backup battery unit respectively form power supply branches, and each power supply branch is provided with an independent MOSFET switching switch and reverse current protection to form a MOSFET switching matrix. The main controller of the control circuit controls the on and off of each MOSFET switching switch to form the power supply switching unit.

4. The energy storage type multi-functional control device according to claim 3, characterized in that, It further includes a remote communication unit, the remote communication unit includes a wired communication unit and a wireless communication unit; the wired communication unit uses an RS485 communication module to realize communication connection with a remote DCS system; the wireless communication unit uses a 4G and / or 5G communication module to realize communication connection with a remote DCS system.

5. The energy storage type multi-functional control device according to claim 4, wherein, The charging management unit is used to charge the backup battery unit and each supercapacitor bank; the charging management unit is provided with a voltage detection circuit for detecting the voltage across the backup battery unit and the voltage across each supercapacitor bank. When the detected voltage is lower than the preset value, charging is started until the preset voltage value is reached.

6. The control system based on the multi-energy storage type multi-functional control device, including a plurality of the energy storage type multi-functional control devices described in claim 5, is characterized in that, Each of the energy storage type multi-functional control devices is communicatively connected through the remote communication unit. Each of the energy storage type multi-functional control devices presets an interlock instruction set for driving the valve body to act, and designates a single or multiple energy storage type multi-functional control devices to control their respective corresponding or designated valve bodies according to the interlock instruction set.

7. The control system based on the multi-energy storage type multi-functional control device according to claim 6, wherein The energy storage type multi-functional control device is also communicatively connected to the remote DCS system through the remote communication unit and receives control instructions.

8. The control system based on the multi-energy storage type multi-functional control device according to claim 6, characterized in that, The electric control system further includes an information acquisition circuit, including a valve body position information, a system power supply information, and a temperature information acquisition circuit.

Images