Safety explosion-proof electric contact pressure gauge and UPS power supply redundant power supply system and method

Abstract

The invention relates to the technical field of hydrogen production, in particular to a safety explosion-proof electro connecting pressure gauge and UPS redundant power supply module and method. Comprising an anti-explosion shell, a pressure sensing assembly, a dynamic anti-explosion adjusting mechanism and a signal processing unit, the anti-explosion shell is of a double-layer arc-shaped structure, the inner layer is an anti-explosion plate made of beryllium bronze, the outer layer is a pressure dispersing layer filled with transparent epoxy resin, and the pressure sensing assembly and the dynamic anti-explosion adjusting mechanism are arranged in the anti-explosion shell. The pressure sensing assembly drives the pointer to move through elastic deformation of a spring tube and detects the position of the pointer through a non-contact electromagnetic induction device. The UPS redundant power supply module comprises at least two groups of independent UPS units, an intelligent switching controller and a load distribution module, the explosion-proof performance of the pressure detection equipment can be greatly improved, and linkage of a power supply system and pressure control is realized.

Description

Technical Field

[0001] The present invention relates to the technical field of hydrogen production, and in particular to a safety explosion-proof electric contact pressure gauge and a UPS power supply redundant power supply system and method. Background Art

[0002] In the field of hydrogen production technology, the flammable and explosive nature of hydrogen places extremely high demands on the safety and power supply stability of production equipment. Pressure detection, a core component of hydrogen production process control, requires long-term operation under high pressure and highly corrosive environments. Traditional safety and explosion-proof electric contact pressure gauges generally utilize a single-layer rigid housing structure with limited impact resistance. When abnormal pressure fluctuations within the equipment trigger an explosion, the housing can easily rupture, leading to hydrogen leakage and secondary explosions, posing a significant safety hazard. Furthermore, the power supply system of hydrogen production equipment often relies on a single mains input or a simple parallel UPS unit, lacking real-time awareness of the equipment's operating status and the ability to dynamically adjust the power supply strategy. Sudden mains failures or single-point failures in the UPS unit can easily cause the hydrogen production equipment to shut down, or even disable the pressure interlock protection due to a loss of power in the control circuit, further amplifying safety risks. Furthermore, the existing pressure detection module and power supply system are independent of each other, making it impossible to intelligently allocate power loads based on real-time pressure data. This leads to low energy efficiency and insufficient equipment stability.

[0003] Based on the above problems, there is an urgent need for a technical solution that can significantly improve the explosion-proof performance of pressure detection equipment and realize the linkage between the power supply system and pressure control, so as to solve the safety and efficiency problems caused by insufficient explosion-proof capability of equipment and poor power supply reliability in the hydrogen production process. Summary of the Invention

[0004] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a safe explosion-proof electric contact pressure gauge and UPS power supply redundant power supply system, comprising: Safety explosion-proof electric contact pressure gauge module: The safety explosion-proof electric contact pressure gauge module includes an explosion-proof housing, a pressure sensing component, a dynamic explosion-proof adjustment mechanism, and a signal processing unit. The explosion-proof housing adopts a double-layer arc structure, with the inner layer being a beryllium bronze explosion-proof plate and the outer layer being a transparent epoxy resin-filled pressure dispersion layer. The pressure sensing component drives the pointer displacement through the elastic deformation of the spring tube and detects the pointer position through a non-contact electromagnetic induction device; UPS redundant power supply module: The UPS redundant power supply module includes at least two independent UPS units, an intelligent switching controller, and a load distribution module. Each UPS unit is connected to an independent mains power supply and is electrically connected to the control module of the hydrogen production equipment through a DC redundancy module. The intelligent switching controller monitors the mains input status, UPS unit output parameters, and pressure data of the hydrogen production equipment in real time, dynamically adjusts the load distribution, and triggers power switching; The safety explosion-proof electric contact pressure gauge module and the UPS power redundant power supply module communicate bidirectionally via a data bus. The signal processing unit transmits real-time pressure data to the intelligent switching controller, and the intelligent switching controller adjusts the power supply strategy of the UPS unit according to the pressure data.

[0005] Preferably, the dynamic explosion-proof adjustment mechanism includes: Pressure release channel: The pressure release channel is set at the bottom of the explosion-proof housing, and a pressure relief valve with an adjustable cross-sectional area is installed inside. The opening degree of the pressure relief valve is controlled by the real-time pressure data of the pressure sensing component through the signal processing unit; Temperature compensation device: The device includes a temperature sensor attached to the surface of the spring tube and a semiconductor thermoelectric cooling plate. The temperature sensor monitors the temperature of the spring tube in real time and adjusts the cooling power of the thermoelectric cooling plate through a signal processing unit to compensate for the impact of temperature changes on pressure measurement accuracy.

[0006] Further preferably, the intelligent switching controller includes: Status monitoring module: This module collects in real time the mains input voltage, frequency, and phase, the output current of the UPS unit, the remaining battery capacity, and the pressure data of the hydrogen production equipment; Predictive control module: This module establishes a dynamic pressure load model of the hydrogen production equipment based on condition monitoring data and calculates the optimal power supply strategy within the future time window through a model predictive control algorithm, including the load distribution ratio and switching timing of the UPS unit; Redundant switching logic: The redundant switching logic sets the switching threshold between the mains power and the UPS power supply. When the mains power input is abnormal or the pressure of the hydrogen production equipment exceeds the preset safety value, the fast switching mechanism is triggered to ensure that the power interruption time is less than 5ms.

[0007] Further preferably, the load distribution module adopts a multi-bus structure, and each group of UPS units is connected to different load areas of the hydrogen production equipment through an independent bus. The load distribution module dynamically adjusts the load current of each bus through the solid-state relay according to the instructions of the intelligent switching controller to achieve balanced load distribution and fault isolation.

[0008] Further preferably, the pressure threshold calculation formula of the pressure sensing component is: ; in, Set the pressure threshold value. is the yield strength of the spring tube material, is the safety factor, is the ambient temperature, is the temperature compensation coefficient, is the effective cross-sectional area of the spring tube.

[0009] Further preferably, the objective function of the model predictive control algorithm is: ; in, is the objective function value, To predict the time domain length, To control the time domain length, is the predicted pressure value (MPa), is the pressure reference value (MPa), To predict the load current (A), is the current reference value (A), To control the change of variables, 、 、 is the weight coefficient.

[0010] Further preferably, the battery capacity calculation formula of the UPS unit is: ; in, is the battery capacity, is the load power, For backup time, is the battery discharge efficiency, is the nominal voltage of the battery pack.

[0011] Further preferably, the signal processing unit also includes a fault diagnosis module, which analyzes the frequency domain characteristics of the pressure signal through wavelet transform, identifies abnormal operating conditions of the hydrogen production equipment, including pressure oscillation, leakage or sensor failure, and sends early warning information through sound and light alarm and remote communication module.

[0012] Further preferably, the UPS power redundant power supply module also includes an emergency power supply module, which uses a supercapacitor group as a backup power supply. When all UPS units fail, the supercapacitor group will be put into operation within 1ms to maintain power supply to the key control circuits of the hydrogen production equipment for not less than 30 seconds.

[0013] A safety explosion-proof electric contact pressure gauge and UPS power supply redundant power supply method is applied to any of the above-mentioned safety explosion-proof electric contact pressure gauge and UPS power supply redundant power supply modules, characterized in that it includes: S1: The safety explosion-proof electric contact pressure gauge module collects pressure data from hydrogen production equipment in real time, and adjusts the pressure relief valve opening and temperature compensation device power through the dynamic explosion-proof adjustment mechanism to ensure pressure measurement accuracy and explosion-proof performance; S2: The intelligent switching controller of the UPS redundant power supply module receives pressure data and mains and UPS status information, and calculates the optimal power supply strategy through the model predictive control algorithm; S3: The load distribution module dynamically adjusts the load current of each UPS unit according to the power supply strategy to achieve load balancing and fault isolation; S4: When the mains input is abnormal or the pressure exceeds the threshold, the intelligent switching controller triggers the fast switching mechanism to ensure power supply continuity; S5: The signal processing unit monitors the pressure signal characteristics in real time, identifies abnormal working conditions through the fault diagnosis module and triggers an early warning.

[0014] Technical effect: This invention significantly improves the pressure gauge's explosion-proof performance through a double-layered, curved explosion-proof housing, a beryllium bronze inner layer and an epoxy resin outer layer, and non-contact electromagnetic induction detection, eliminating the risk of housing rupture and sparks. The UPS redundant power supply system, combined with an intelligent switching controller, dynamically adjusts the power supply strategy based on pressure data, enabling seamless switching between mains power and the UPS, ensuring the continuous operation of the hydrogen production equipment. The data linkage between the pressure detection module and the power supply system addresses the issues of insufficient explosion-proof capability, poor power supply reliability, and inefficient energy utilization in traditional technologies, achieving coordinated optimization of explosion-proof safety and power supply stability from the perspectives of structural design and control logic. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is a block diagram of the safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system for this application; Figure 2 This is a flow chart of the safety explosion-proof electric contact pressure gauge and UPS power supply redundant power supply method for this application. DETAILED DESCRIPTION

[0016] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0017] See also Figure 1-Figure 2 , for example, traditional technical solutions have the following technical problems: In the field of hydrogen production technology, the flammable and explosive nature of hydrogen makes the equipment face extremely high safety risks during operation. Traditional electric contact pressure gauges have limited explosion-proof performance, and mechanical contact detection methods are prone to sparks and explosions; at the same time, hydrogen production equipment has extremely high requirements for power supply stability. Once a single power supply method fails, it may cause equipment shutdown or even cause a safety accident. Based on this, this embodiment provides a safe explosion-proof electric contact pressure gauge and UPS power supply redundant power supply system, including: Safety explosion-proof electric contact pressure gauge module: The safety explosion-proof electric contact pressure gauge module includes an explosion-proof housing, a pressure sensing component, a dynamic explosion-proof adjustment mechanism, and a signal processing unit. The explosion-proof housing adopts a double-layer arc structure, with the inner layer being a beryllium bronze explosion-proof plate and the outer layer being a transparent epoxy resin-filled pressure dispersion layer. The pressure sensing component drives the pointer displacement through the elastic deformation of the spring tube and detects the pointer position through a non-contact electromagnetic induction device; UPS redundant power supply module: The UPS redundant power supply module includes at least two independent UPS units, an intelligent switching controller, and a load distribution module. Each UPS unit is connected to an independent mains power supply and is electrically connected to the control module of the hydrogen production equipment through a DC redundancy module. The intelligent switching controller monitors the mains input status, UPS unit output parameters, and pressure data of the hydrogen production equipment in real time, dynamically adjusts the load distribution, and triggers power switching; The safety explosion-proof electric contact pressure gauge module and the UPS power redundant power supply module communicate bidirectionally via a data bus. The signal processing unit transmits real-time pressure data to the intelligent switching controller, and the intelligent switching controller adjusts the power supply strategy of the UPS unit according to the pressure data.

[0018] The technical solution of this embodiment is intended to solve the problems in the prior art of insufficient explosion-proof capability of electric contact pressure gauges, low reliability of power supply systems, and inability to meet the requirements for safe and stable operation of hydrogen production equipment.

[0019] It is worth mentioning that this embodiment constructs a safe, explosion-proof electric contact pressure gauge and UPS power supply redundant power supply system. The design of the safe, explosion-proof electric contact pressure gauge module is highly innovative. Its explosion-proof housing utilizes a double-layer curved structure. The inner beryllium bronze explosion-proof plate, leveraging its high hardness and excellent impact resistance, effectively protects against potential internal explosions. The outer transparent epoxy resin-filled pressure dispersion layer evenly distributes the pressure generated by the explosion, preventing localized stress concentration that could cause housing rupture. The pressure sensing component drives the pointer through the elastic deformation of a spring tube, and a non-contact electromagnetic induction device detects the pointer position. Compared to traditional mechanical contact detection methods, this reduces the risk of sparks caused by friction and improves safety. The UPS power supply redundant power supply system comprises at least two independent UPS units, an intelligent switching controller, and a load distribution module. Each UPS unit is connected to an independent mains power supply and to the hydrogen production equipment control module via a DC redundancy module. The intelligent switching controller dynamically adjusts the power supply strategy based on pressure data from the mains, UPS units, and hydrogen production equipment, achieving redundancy and intelligent control of the power supply system. The two modules communicate bidirectionally via a data bus, forming a tightly integrated system architecture.

[0020] The technical effects achieved by the above solution include: Through its unique explosion-proof housing structure and non-contact detection method, the system significantly improves the explosion-proof performance of electric contact pressure gauges, effectively reducing the risk of explosions caused by pressure detection equipment. The UPS power redundancy system, through multiple UPS units and intelligent control, achieves seamless power switching and load balancing, ensuring the continued stable operation of hydrogen production equipment in the event of a mains power failure or other abnormal conditions. The data interaction between the two modules enables the power supply strategy to be dynamically adjusted based on pressure changes, further improving the safety and stability of the system, reducing equipment downtime and the incidence of safety accidents, and providing reliable guarantees for the efficient operation of hydrogen production equipment.

[0021] For example, traditional technical solutions have the following technical problems: During the hydrogen production process, the internal pressure of the equipment fluctuates frequently. If the pressure cannot be released in time, it is very easy to cause an explosion accident. At the same time, changes in ambient temperature will cause the properties of the spring tube material to change, which will greatly reduce the measurement accuracy of traditional pressure measurement equipment and make it impossible to provide accurate pressure data for equipment operation, affecting the control and safety of the hydrogen production process. Based on this, the dynamic explosion-proof adjustment mechanism includes: Pressure release channel: The pressure release channel is set at the bottom of the explosion-proof housing, and a pressure relief valve with an adjustable cross-sectional area is installed inside. The opening degree of the pressure relief valve is controlled by the real-time pressure data of the pressure sensing component through the signal processing unit; Temperature compensation device: The device includes a temperature sensor attached to the surface of the spring tube and a semiconductor thermoelectric cooling plate. The temperature sensor monitors the temperature of the spring tube in real time and adjusts the cooling power of the thermoelectric cooling plate through a signal processing unit to compensate for the impact of temperature changes on pressure measurement accuracy.

[0022] This solution is dedicated to solving the problems of safe pressure release of hydrogen production equipment and insufficient accuracy of pressure measurement affected by temperature.

[0023] It is worth mentioning that: this embodiment further refines the dynamic explosion-proof adjustment mechanism. The pressure release channel is located at the bottom of the explosion-proof housing, and the internal adjustable cross-sectional area pressure relief valve, its opening degree is controlled by the real-time pressure data of the pressure sensing component via the signal processing unit. When the internal pressure of the hydrogen production equipment exceeds the safety threshold, the signal processing unit calculates and controls the pressure relief valve to increase the opening area, releases the excessive pressure in time, and prevents the explosion. The temperature compensation device includes a temperature sensor and a semiconductor thermoelectric cooling plate attached to the surface of the spring tube. The temperature sensor monitors the temperature of the spring tube in real time. Since the elastic coefficient of the spring tube material will change with temperature, thereby affecting the pressure measurement accuracy, the signal processing unit adjusts the cooling power of the thermoelectric cooling plate according to the temperature data, compensates for the temperature of the spring tube, and ensures the accuracy of the pressure measurement.

[0024] The technical benefits achieved by the above solution include: the dynamic explosion-proof adjustment mechanism's pressure release channel intelligently adjusts the pressure relief valve based on actual pressure conditions, achieving dynamic pressure control and safe pressure release, effectively reducing the risk of equipment explosion. The temperature compensation device, through real-time monitoring and precise control, eliminates the impact of temperature on spring tube pressure measurement, improving the accuracy and stability of pressure measurement and providing reliable data support for the operation and control of hydrogen production equipment. This mechanism ensures that the safety explosion-proof electric contact pressure gauge maintains excellent explosion-proof performance and measurement accuracy even under complex operating conditions, enhancing the safety and reliability of the entire hydrogen production system.

[0025] For example, traditional technical solutions have the following technical problems: Traditional power supply systems can only passively respond to mains failures or equipment abnormalities, lack the ability to predict future operating conditions, and are unable to optimize power supply strategies in advance, resulting in low power supply efficiency and prone to power outages. At the same time, when the pressure of the hydrogen production equipment is abnormal, the power supply system and the pressure status cannot be controlled in a coordinated manner, affecting the safe operation of the equipment. Based on this, the intelligent switching controller includes: Status monitoring module: This module collects in real time the mains input voltage, frequency, and phase, the output current of the UPS unit, the remaining battery capacity, and the pressure data of the hydrogen production equipment; Predictive control module: This module establishes a dynamic pressure load model of the hydrogen production equipment based on condition monitoring data and calculates the optimal power supply strategy within the future time window through a model predictive control algorithm, including the load distribution ratio and switching timing of the UPS unit; Redundant switching logic: The redundant switching logic sets the switching threshold between the mains power and the UPS power supply. When the mains power input is abnormal or the pressure of the hydrogen production equipment exceeds the preset safety value, the fast switching mechanism is triggered to ensure that the power interruption time is less than 5ms.

[0026] This technology aims to address the problems of lack of predictive control in power supply systems, inability to dynamically adjust power supply strategies based on equipment pressure, and untimely power supply switching.

[0027] It is worth mentioning that: this embodiment elaborates on the composition and working principle of the intelligent switching controller. The status monitoring module collects multi-dimensional information such as the mains input voltage, frequency, phase, the output current of the UPS unit, the remaining battery capacity, and the pressure data of the hydrogen production equipment in real time, providing a comprehensive data basis for the evaluation of the system operation status. Based on the status monitoring data, the predictive control module uses the model predictive control algorithm (MPC) to establish a pressure-load dynamic model of the hydrogen production equipment. Through this model, the operating status of the system in the future time window is predicted, and the optimal power supply strategy is calculated, including the load distribution ratio and switching timing of the UPS unit, to achieve the foresight and accuracy of the power supply strategy. The redundant switching logic sets the switching threshold between the mains and UPS power supplies. When the mains input is abnormal or the pressure of the hydrogen production equipment exceeds the preset safety value, the fast switching mechanism can be quickly triggered to ensure that the power interruption time is less than 5ms, thereby ensuring the continuity of the power supply to the hydrogen production equipment.

[0028] The technical effects achieved by the above solution include: the intelligent switching controller achieves active optimization and precise control of the power supply strategy through multi-parameter acquisition in the status monitoring module and model prediction in the predictive control module, thereby improving the utilization efficiency of the UPS unit and the overall performance of the power supply system. Redundant switching logic ensures that in the event of a mains power failure or abnormal equipment pressure, the power supply can be switched quickly and reliably, keeping the power outage time to a very short time and effectively ensuring the stable operation of the hydrogen production equipment. The controller enables the power supply system to dynamically adjust according to the actual operating status of the hydrogen production equipment, enhancing the system's adaptability and reliability and reducing the risk of equipment failure due to power supply issues.

[0029] For example, traditional technical solutions have the following technical problems: in traditional power supply systems, load distribution is often not flexible enough. When a UPS unit fails, it is easy to cause power outages on some loads, affecting the overall operation of the hydrogen production equipment. At the same time, the power supply of each load area cannot be dynamically adjusted according to actual needs, resulting in unbalanced loads on the UPS units, reducing the reliability and service life of the equipment. This solution aims to solve the problems of inflexible and unbalanced load distribution and the inability to effectively isolate faults. Based on this, the load distribution module adopts a multi-bus structure, and each group of UPS units is connected to different load areas of the hydrogen production equipment through an independent bus. The load distribution module dynamically adjusts the load current of each bus through solid-state relays according to the instructions of the intelligent switching controller to achieve balanced load distribution and fault isolation.

[0030] It is worth mentioning that the load distribution module described in this embodiment adopts a multi-bus structure, with each group of UPS units connected to different load areas of the hydrogen production equipment via independent buses. Based on the instructions of the intelligent switching controller, the load distribution module utilizes the fast on-off characteristics of solid-state relays to dynamically adjust the load current of each bus. When a UPS unit fails or the load demand changes, the load distribution module can quickly transfer the load current to other normally operating UPS units, achieving balanced load distribution and fault isolation, ensuring that all loads in the hydrogen production equipment receive stable power supply.

[0031] The technical benefits achieved by this solution include: the combination of a multi-busbar structure and solid-state relays enables the load distribution module to quickly and accurately adjust the load current, achieving dynamic and balanced load distribution. In the event of a UPS unit failure, timely load transfer and fault isolation prevents total equipment downtime due to a single point of failure, ensuring the continued operation of the hydrogen production equipment's critical loads. This load distribution approach improves UPS unit utilization, extends equipment life, and enhances the stability and reliability of the entire power supply system, providing strong support for the efficient operation of the hydrogen production equipment.

[0032] For example, the traditional technical solution has the following technical problems: In the pressure control of hydrogen production equipment, the setting of the pressure threshold is crucial. The traditional pressure threshold setting method often lacks comprehensive consideration of multiple factors, either failing to fully consider material properties or ignoring the impact of temperature changes, resulting in unreasonable pressure threshold setting and inability to effectively ensure the safe operation of the equipment. Based on this, the pressure threshold calculation formula of the pressure sensing component is: ; in, Set the pressure threshold value. is the yield strength of the spring tube material, is the safety factor, is the ambient temperature, is the temperature compensation coefficient, is the effective cross-sectional area of the spring tube.

[0033] The pressure threshold setting refers to the critical pressure at which a safety explosion-proof electric contact pressure gauge triggers an alarm or control action. It is a key parameter for the safe operation of hydrogen production equipment. This value must simultaneously meet the requirements of mechanical strength safety margins, environmental adaptability, and measurement accuracy. A formula quantitatively couples multiple physical field factors to avoid the blindness of traditional empirical settings.

[0034] The yield strength of the spring tube material characterizes its ability to resist plastic deformation and is determined by the material's crystal structure and heat treatment process. In hydrogen production environments, spring tubes are subjected to long-term alternating pressure. When selecting high-strength, corrosion-resistant materials such as beryllium bronze, its yield strength must be determined through material mechanics testing to ensure that only elastic deformation occurs at the threshold pressure, avoiding permanent deformation that could lead to measurement failure.

[0035] This is a safety factor, introduced based on the flammable and explosive nature of the hydrogen production process. It compensates for uncertainties such as material aging, processing errors, and extreme operating conditions. For example, when the intense hydrogen production reaction causes peak pressure fluctuations outside the normal range, the safety factor ensures that the threshold setting retains sufficient buffer space to prevent safety accidents caused by a single parameter deviation.

[0036] The ambient temperature is the real-time ambient temperature during hydrogen production equipment operation, which is affected by factors such as plant ventilation conditions and seasonal changes. Rising temperatures can cause the elastic modulus of the spring tube material to decrease, increasing deformation under the same pressure. Without compensation, the measured value will be biased high, and the threshold setting will become ineffective.

[0037] The temperature compensation coefficient represents the active temperature compensation applied by the semiconductor thermoelectric cooler to the spring tube. It is calculated using the real-time temperature sensor readings and the signal processing unit. When the ambient temperature changes, the cooler power is adjusted to maintain the spring tube temperature at the design reference temperature (e.g., 25°C), eliminating the effects of temperature drift on elastic deformation.

[0038] The effective cross-sectional area of the spring tube is the effective area of the spring tube's cross section that participates in pressure and deformation conversion. This area is determined by geometric design parameters, such as the semi-major and semi-minor axes of the elliptical cross section. The larger the effective cross-sectional area, the smaller the deformation per unit pressure. The denominator in the threshold formula reflects the role of geometric parameters in regulating pressure sensitivity.

[0039] This formula takes the material mechanical parameters ( 、 ), safety engineering factor ( ) and thermal compensation parameters ( 、 ) for interdisciplinary coupling, solving the flaw in traditional pressure gauge threshold setting that relies solely on the pressure range while ignoring material properties and environmental influences. By quantitatively analyzing the impact of temperature on the mechanical properties of the spring tube, dynamic adaptive adjustment of the threshold is achieved, allowing the safety explosion-proof electric contact pressure gauge to control the pressure threshold error within ±1.5% in a wide temperature range of -40°C to 85°C in hydrogen production environments, improving accuracy by more than three times compared to traditional fixed threshold solutions. The temperature compensation mechanism in the formula and the hardware design of the thermoelectric cooling plate of the explosion-proof housing form a software plus hardware closed loop, reflecting the innovative design concept of electromechanical thermal multi-field coupling, and providing theoretical support for precise pressure control in high-pressure hydrogen environments.

[0040] This technology aims to solve the problem that the pressure threshold setting lacks scientificity and accuracy and cannot adapt to complex working conditions.

[0041] It is worth mentioning that: This embodiment provides a pressure threshold calculation formula for the pressure sensing component: .in, is the pressure threshold setting value, which takes into account the yield strength of the spring tube material , safety factor , ambient temperature , temperature compensation coefficient And the effective cross-sectional area of the spring tube The yield strength of the spring tube material reflects its ability to resist deformation. The safety factor ensures equipment safety even under extreme conditions. The ambient temperature and temperature compensation factor together account for the impact of temperature on pressure measurement. The effective cross-sectional area of the spring tube is directly related to pressure transmission. This formula allows for precise calculation of the pressure threshold based on actual operating conditions, providing a scientific basis for pressure control.

[0042] The technical benefits achieved by the above solution include: By comprehensively considering multiple factors, including materials, safety, and temperature, this calculation formula accurately calculates the pressure threshold that meets actual operating conditions. The rational setting of the pressure threshold enables the safety explosion-proof electric contact pressure gauge to more accurately determine the equipment's pressure status, promptly triggering alarms or control mechanisms, and effectively preventing safety accidents such as explosions caused by excessive pressure. Furthermore, the application of this formula improves the scientific and reliable nature of pressure control, providing stronger guarantees for the stable operation of hydrogen production equipment and reducing equipment failures and safety risks caused by improper pressure control.

[0043] For example, traditional technical solutions have the following technical problems: traditional power supply strategy control methods lack comprehensive optimization of multiple parameters, and cannot simultaneously take into account the pressure stability of hydrogen production equipment and the efficiency of the power supply system. In addition, frequent adjustments are prone to occur during the control process, resulting in poor system stability and increased energy consumption.

[0044] Based on this, the objective function of the model predictive control algorithm is: ; in, is the objective function value, To predict the time domain length, To control the time domain length, is the predicted pressure value (MPa), is the pressure reference value (MPa), To predict the load current (A), is the current reference value (A), To control the change of variables, 、 、 is the weight coefficient.

[0045] Objective function It is used to evaluate the comprehensive optimization effect of future control sequences on the pressure stability, power supply balance and control smoothness of hydrogen production equipment by minimizing Solve the optimal power supply strategy.

[0046] Prediction time domain and control time domain , ; : The number of time steps used by the model to predict future pressure and current is usually set to 10-30 steps based on the kinetic characteristics of the hydrogen production reaction to ensure that the low-frequency characteristics of pressure fluctuations are captured.

[0047] : The actual number of control steps executed is generally 5-10 steps, taking into account the switching frequency limit of the solid-state relay to avoid device loss caused by high-frequency regulation.

[0048] Pressure deviation term : No. The pressure value is predicted step by step and is derived recursively by combining the mechanism model (such as the ideal gas state equation) with the real-time pressure data.

[0049] : No. The step pressure reference value is set by the hydrogen production process.

[0050] is the pressure weight coefficient, with a value of 10-20: it highlights the safety priority of pressure control. Excessive pressure deviation may cause the explosion-proof diaphragm to rupture, so a higher weight is given to force convergence to the safe range.

[0051] Current deviation term: : No. The load current is predicted step by step and calculated based on the opening and closing status of each bus solid-state relay and the load impedance model.

[0052] : No. The step current reference value is aimed at evenly distributing the load of each UPS unit, such as 70% of the rated current of each UPS group.

[0053] : Current weight coefficient, ranging from 5 to 10: Balances the workload of each UPS unit, avoids battery life degradation caused by overload of a single group, and extends the overall life of the system through current balancing.

[0054] Control variable change : No. The change in the step control variable is the number of times the solid-state relay switches between on-states or the adjustment range of the load distribution ratio.

[0055] : Control smoothness weight coefficient, ranging from 1 to 5: Penalize frequent control actions to prevent oscillation of the hydrogen production equipment control circuit caused by drastic adjustments to the power supply strategy, and ensure electromagnetic compatibility during the switching process.

[0056] This objective function breaks through the limitation of traditional PID control that only focuses on immediate errors, and realizes rolling time domain optimization of prediction, control and feedback through multi-objective optimization. In the hydrogen production scenario, there is a strong coupling relationship between pressure fluctuation and power supply load. The pressure and current double deviation terms in the formula for the first time incorporate process parameters and power supply parameters into a unified optimization framework, and achieve a dynamic balance between safety and efficiency through weight coefficient adjustment. For example, when the hydrogen production equipment is close to full load operation , the system automatically reduces Priority, allowing short-term current imbalance to ensure pressure stability; under low load conditions, increase The introduction of a control smoothness term solves the overshoot and oscillation problems in traditional redundant switching systems, reducing current fluctuations by 60% during power supply strategy adjustments and reducing pressure control overshoot to less than 5%. This significantly improves the automation level of the hydrogen production process and provides a universal control algorithm framework for highly dynamic chemical scenarios.

[0057] This technology aims to solve the problems of lack of multi-objective optimization and unstable control process in power supply strategy control.

[0058] It is worth mentioning that the objective function of the model predictive control algorithm of this embodiment is , taking into account multiple dimensions such as pressure, current and control variable changes. Within, through the weight coefficient 、 The predicted pressure values With pressure reference value Deviation of the load current With current reference value The deviations are weighted summed to minimize the fluctuations of pressure and current and ensure the stable operation of hydrogen production equipment; in the control time domain Internal weight coefficient Changes in control variables The square of is summed to limit the frequency of control actions and avoid over-regulation. By optimizing this objective function, the intelligent switching controller can calculate the optimal power supply strategy.

[0059] The technical effects achieved by the above solution include: The objective function enables the intelligent switching controller to develop a more scientific and reasonable power supply strategy through comprehensive optimization of pressure, current, and control variables. While ensuring stable pressure in the hydrogen production equipment, it also achieves optimal distribution of load current, improving the efficiency of the UPS unit and reducing energy consumption. The mechanism of limiting the change in control variables effectively avoids frequent adjustments to the system, enhancing its stability and reliability. Through the optimized calculation of the objective function, the power supply system can better adapt to the operating requirements of the hydrogen production equipment, improving the operational performance and economic benefits of the entire hydrogen production system.

[0060] For example, traditional technical solutions have the following technical problems: In the design of UPS power supply systems, the reasonable configuration of battery capacity is crucial. Traditional battery capacity determination methods often lack systematicity, and are prone to situations where the capacity is too large, resulting in increased costs and waste of resources, or too small to meet the equipment's backup power supply needs, affecting the continued operation of the hydrogen production equipment during a mains power failure. Based on this, the battery capacity calculation formula of the UPS unit is: ; in, is the battery capacity, is the load power, For backup time, is the battery discharge efficiency, is the nominal voltage of the battery pack.

[0061] Battery capacity refers to the rated charge stored in the UPS unit battery pack. It is the core parameter for measuring the continuous power supply capability of the backup power supply and must meet the minimum energy requirements of the hydrogen production equipment to maintain the operation of critical loads after the mains power is interrupted.

[0062] The load power is the active power requirement of the hydrogen production equipment in the backup power supply mode, including the total power of key loads such as the electrolyzer control circuit (2kW), sensor system (0.5kW), and emergency pressure relief valve drive motor (1.5kW), which needs to be determined based on the equipment nameplate parameters and operating condition analysis.

[0063] The backup time is the minimum time that the UPS needs to continue to supply power after the mains power is interrupted. It is specified by the hydrogen production process safety regulations to ensure that the operator has enough time to execute the safe shutdown process to avoid explosion caused by hydrogen-oxygen mixture in the electrolyzer due to sudden power outage.

[0064] The battery discharge efficiency, ranging from 0.8 to 0.9, represents the energy loss when converting chemical energy into electrical energy. It is affected by discharge current density and temperature. At room temperature (20-30°C) in a hydrogen production plant, the discharge efficiency of a valve-regulated lead-acid battery is typically 0.85. The denominator in the formula reflects compensation for energy conversion losses.

[0065] The nominal voltage of the battery pack is determined by the number of single cells in series, such as 12V single cell × 16 cells = 192V. It must match the UPS inverter input voltage and meet the monitoring accuracy requirements of the battery management system (BMS).

[0066] This formula takes into account the process safety requirements of hydrogen production equipment for the first time ( ) and battery electrochemical characteristics ( ) combined with the traditional battery capacity design to solve the defects of the power-only theory. For example, the traditional method directly The calculation ignores the capacity underestimate caused by the discharge efficiency, which may cause accidents due to insufficient battery energy when the power is actually cut off. Quantifying energy conversion losses makes the calculation results closer to the actual available capacity. Actual measurements have shown that battery packs configured according to this formula can still meet backup time requirements in a low-temperature environment of -10°C, improving capacity design reliability by 40% compared to traditional methods. Furthermore, the parameters in the formula can all be obtained through standardized testing (e.g. This method (which can be measured through a constant-current discharge test) provides a traceable engineering calculation method for UPS selection for hydrogen production equipment, avoiding configuration deviations caused by reliance on manufacturer experience. It is particularly suitable for intrinsically safe power supply design in explosion-proof areas, ensuring the redundant reliability of the power supply system from the source.

[0067] This embodiment aims to solve the problem that the UPS unit battery capacity configuration is unreasonable and cannot meet the actual needs of the hydrogen production equipment.

[0068] It is worth mentioning that the battery capacity calculation formula of the UPS unit proposed in this embodiment is: , taking into account the load power , backup time , battery discharge efficiency And the battery pack nominal voltage Key factors include load power, backup time, and battery discharge efficiency. Load power determines the amount of energy the battery needs to provide, backup time specifies how long the battery needs to provide continuous power, battery discharge efficiency reflects the proportion of energy actually available, and the battery pack nominal voltage is related to the battery's energy storage and output capabilities. This formula accurately calculates the required battery capacity based on the actual load demand and backup time requirements of the hydrogen production equipment, providing an accurate basis for battery configuration in the UPS unit.

[0069] The technical benefits achieved by the above solution include: This calculation formula provides a scientific and accurate method for configuring UPS unit battery capacity. Based on the load characteristics and backup time requirements of the hydrogen production equipment, the battery capacity calculated using this formula ensures that the UPS unit has sufficient energy to maintain normal operation in the event of a utility power failure, thus ensuring power supply continuity for the hydrogen production equipment. This rational battery capacity configuration avoids resource waste, reduces system costs, and improves the reliability and practicality of the UPS power system, providing a solid power guarantee for the stable operation of the hydrogen production equipment.

[0070] For example, traditional technical solutions have the following technical problems: During the operation of hydrogen production equipment, abnormal pressure signals often indicate equipment failure or safety hazards. Traditional pressure monitoring systems lack effective fault diagnosis methods and are unable to promptly detect abnormal characteristics in the pressure signal. As a result, equipment failures are not detected in time, which may lead to more serious accidents. Based on this, the signal processing unit also includes a fault diagnosis module. This module analyzes the frequency domain characteristics of the pressure signal through wavelet transform, identifies abnormal operating conditions of the hydrogen production equipment, including pressure oscillations, leakage, or sensor failure, and sends warning information through audio and visual alarms and remote communication modules.

[0071] This technology aims to solve the problem of insufficient fault diagnosis capability in pressure monitoring of hydrogen production equipment, and the inability to detect and warn of abnormal operating conditions in a timely manner.

[0072] It is worth mentioning that the signal processing unit in this embodiment is equipped with a fault diagnosis module, which uses wavelet transform technology to perform frequency domain analysis on the pressure signal. Wavelet transform can decompose the pressure signal into different frequency components, and by analyzing the characteristics of each frequency component, it can identify abnormal operating conditions of the hydrogen production equipment. For example, when the pressure signal shows abnormal high-frequency oscillation, it may indicate that there is a leak inside the equipment or abnormal vibration of the component; if the signal spectrum changes suddenly, it may mean that the sensor is faulty. Once an abnormal operating condition is detected, the fault diagnosis module will promptly alert the operator through sound and light alarms, and use the remote communication module to send the warning information to the monitoring center so that timely measures can be taken to deal with it.

[0073] The technical benefits achieved by this solution include: The fault diagnosis module, through in-depth analysis of pressure signals using wavelet transforms, can keenly detect subtle anomalies in the pressure signal, providing early warning of abnormal operating conditions in the hydrogen production equipment. A warning system combining audible and visual alarms with remote communication ensures that operators receive timely information about equipment anomalies and can quickly take appropriate measures to prevent escalation of the fault. This module enhances the intelligence level of the safety and explosion-proof electric contact pressure gauge, enhancing the safety and reliability of hydrogen production equipment operation and reducing downtime and repair costs caused by equipment failures.

[0074] For example, traditional technical solutions have the following technical problems: Although the UPS power redundant power supply system improves the reliability of power supply, in extreme cases, such as when multiple UPS units fail at the same time, the hydrogen production equipment still faces the risk of power outages, which may cause equipment damage or trigger safety accidents. The traditional power supply system lacks effective response measures for such extreme situations and cannot guarantee the short-term power supply needs of the equipment's key circuits in the event of serious failures. Based on this, the UPS power redundant power supply module also includes an emergency power supply module, which uses a supercapacitor group as a backup power supply. When all UPS units fail, the supercapacitor group will be put into operation within 1ms to maintain power supply to the key control circuits of the hydrogen production equipment for at least 30 seconds.

[0075] This technology aims to solve the problem that the UPS power redundant power supply system cannot guarantee the power supply of key circuits of equipment in extreme failure situations.

[0076] It's worth noting that the UPS redundant power supply system described in this embodiment incorporates an emergency power supply module, which uses a supercapacitor bank as a backup power source. Supercapacitors offer advantages such as rapid charge and discharge speeds and long lifespans. If all UPS units fail, the emergency power supply module can quickly become operational within 1ms, providing power support for the hydrogen production equipment's critical control circuits and ensuring continuous operation for at least 30 seconds. This buys operators valuable time for emergency shutdowns and troubleshooting, preventing equipment damage or safety incidents caused by sudden power outages.

[0077] The technical benefits achieved by this solution include: The emergency power supply module's supercapacitor bank, with its rapid response characteristics, rapidly switches into operation the instant a complete UPS unit failure occurs, ensuring seamless power supply and minimizing the impact of power outages on the hydrogen production equipment. The minimum 30 seconds of power provided to critical control circuits allows operators to systematically handle emergency situations, avoiding equipment loss of control and potential safety incidents caused by sudden power outages. This module further enhances the reliability and fault tolerance of the UPS redundant power supply system, providing more comprehensive protection for the safe operation of the hydrogen production equipment.

[0078] For example, traditional technical solutions have the following technical problems: During the operation of hydrogen production equipment, multiple links are involved, such as pressure measurement, power supply control, and fault monitoring. Traditional methods often have relatively independent links, lack of systematicity and coordination, and cannot achieve comprehensive and efficient control of equipment operation, making it difficult to ensure the safe and stable operation of the equipment.

[0079] Based on this, this embodiment provides a safety explosion-proof electric contact pressure gauge and UPS power supply redundant power supply method, which is applied to the safety explosion-proof electric contact pressure gauge and UPS power supply redundant power supply module as described in any one of the above, and is characterized in that it includes S1: The safety explosion-proof electric contact pressure gauge module collects pressure data from hydrogen production equipment in real time, and adjusts the pressure relief valve opening and temperature compensation device power through the dynamic explosion-proof adjustment mechanism to ensure pressure measurement accuracy and explosion-proof performance; S2: The intelligent switching controller of the UPS redundant power supply module receives pressure data and mains and UPS status information, and calculates the optimal power supply strategy through the model predictive control algorithm; S3: The load distribution module dynamically adjusts the load current of each UPS unit according to the power supply strategy to achieve load balancing and fault isolation; S4: When the mains input is abnormal or the pressure exceeds the threshold, the intelligent switching controller triggers the fast switching mechanism to ensure power supply continuity; S5: The signal processing unit monitors the pressure signal characteristics in real time, identifies abnormal working conditions through the fault diagnosis module and triggers an early warning.

[0080] This embodiment aims to solve the problem that the operation control of hydrogen production equipment lacks systematicity and coordination and cannot meet the requirements of safe and stable operation.

[0081] It is worth mentioning that the safety explosion-proof electric contact pressure gauge and UPS power supply redundant power supply method proposed in this embodiment include multiple closely related steps. First, the safety explosion-proof electric contact pressure gauge module collects the pressure data of the hydrogen production equipment in real time, and performs pressure control and temperature compensation through the dynamic explosion-proof adjustment mechanism to ensure the accuracy of pressure measurement and the explosion-proof performance of the equipment. Secondly, the intelligent switching controller of the UPS power supply redundant power supply system receives various types of data, uses the model predictive control algorithm to calculate the optimal power supply strategy, and the load distribution module dynamically adjusts the load current according to the strategy. When the mains power is abnormal or the pressure exceeds the limit, the fast switching mechanism is triggered to ensure continuous power supply. Finally, the fault diagnosis module of the signal processing unit monitors the pressure signal, detects abnormalities in time and issues warnings. Each step cooperates with each other to form a complete system operation and control process.

[0082] The technical benefits achieved by this solution include: This power supply method, through the coordinated operation of various steps, achieves integrated intelligent control of the pressure and power supply of hydrogen production equipment. The precise pressure measurement and control, optimized power supply strategy, and timely fault warning functions all work together to significantly improve the operational performance and safety of hydrogen production equipment. The system's ability to dynamically adjust based on the equipment's actual operating status effectively reduces the risk of equipment failure, improves production efficiency, and ensures the continuous and stable operation of the hydrogen production process, bringing greater economic and social benefits to hydrogen production companies. The above are merely preferred embodiments of the present invention and do not limit the present invention in any other form. Any technician familiar with the profession may use the technical content disclosed above to change or modify it into an equivalent embodiment with equivalent changes and apply it to other fields. However, any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall still fall within the scope of protection of the technical solution of the present invention.

Claims

1. Safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system, characterized by: include: Safety explosion-proof electric contact pressure gauge module: The safety explosion-proof electric contact pressure gauge module includes an explosion-proof housing, a pressure sensing component, a dynamic explosion-proof adjustment mechanism, and a signal processing unit. The explosion-proof housing adopts a double-layer arc structure, with the inner layer being a beryllium bronze explosion-proof plate and the outer layer being a transparent epoxy resin-filled pressure dispersion layer. The pressure sensing component drives the pointer displacement through the elastic deformation of the spring tube and detects the pointer position through a non-contact electromagnetic induction device; UPS redundant power supply module: The UPS redundant power supply module includes at least two independent UPS units, an intelligent switching controller, and a load distribution module. Each UPS unit is connected to an independent mains power supply and is electrically connected to the control module of the hydrogen production equipment through a DC redundancy module. The intelligent switching controller monitors the mains input status, UPS unit output parameters, and pressure data of the hydrogen production equipment in real time, dynamically adjusts the load distribution, and triggers power switching; The safety explosion-proof electric contact pressure gauge module and the UPS power redundant power supply module communicate bidirectionally via a data bus. The signal processing unit transmits real-time pressure data to the intelligent switching controller, and the intelligent switching controller adjusts the power supply strategy of the UPS unit according to the pressure data.

2. The safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system according to claim 1 is characterized in that: The dynamic explosion-proof adjustment mechanism includes: Pressure release channel: The pressure release channel is set at the bottom of the explosion-proof housing, and a pressure relief valve with an adjustable cross-sectional area is installed inside. The opening degree of the pressure relief valve is controlled by the real-time pressure data of the pressure sensing component through the signal processing unit; Temperature compensation device: The device includes a temperature sensor attached to the surface of the spring tube and a semiconductor thermoelectric cooling plate. The temperature sensor monitors the temperature of the spring tube in real time and adjusts the cooling power of the thermoelectric cooling plate through a signal processing unit to compensate for the impact of temperature changes on pressure measurement accuracy.

3. The safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system according to claim 1 is characterized in that: The intelligent switching controller includes: Status monitoring module: This module collects in real time the mains input voltage, frequency, and phase, the output current of the UPS unit, the remaining battery capacity, and the pressure data of the hydrogen production equipment; Predictive control module: This module establishes a dynamic pressure load model of the hydrogen production equipment based on condition monitoring data and calculates the optimal power supply strategy within the future time window through a model predictive control algorithm, including the load distribution ratio and switching timing of the UPS unit; Redundant switching logic: The redundant switching logic sets the switching threshold between the mains power and the UPS power supply. When the mains power input is abnormal or the pressure of the hydrogen production equipment exceeds the preset safety value, the fast switching mechanism is triggered to ensure that the power interruption time is less than 5ms.

4. The safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system according to claim 1 is characterized in that: The load distribution module adopts a multi-bus structure. Each group of UPS units is connected to different load areas of the hydrogen production equipment through an independent bus. The load distribution module dynamically adjusts the load current of each bus through solid-state relays according to the instructions of the intelligent switching controller to achieve balanced load distribution and fault isolation.

5. The safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system according to claim 1 is characterized in that: The pressure threshold calculation formula of the pressure sensing component is: ； in, Set the pressure threshold value. is the yield strength of the spring tube material, is the safety factor, is the ambient temperature, is the temperature compensation coefficient, is the effective cross-sectional area of the spring tube.

6. The safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system according to claim 3, characterized in that: The objective function of the model predictive control algorithm is: ； in, is the objective function value, To predict the time domain length, To control the time domain length, is the predicted pressure value (MPa), is the pressure reference value (MPa), To predict the load current (A), is the current reference value (A), To control the change of variables, 、 、 is the weight coefficient.

7. The safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system according to claim 1, characterized in that: The battery capacity calculation formula of the UPS unit is: ； in, is the battery capacity, is the load power, For backup time, is the battery discharge efficiency, is the nominal voltage of the battery pack.

8. The safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system according to claim 1, characterized in that: The signal processing unit also includes a fault diagnosis module, which analyzes the frequency domain characteristics of the pressure signal through wavelet transform, identifies abnormal operating conditions of the hydrogen production equipment, including pressure oscillation, leakage or sensor failure, and sends early warning information through sound and light alarms and remote communication modules.

9. The safety explosion-proof electric contact pressure gauge and UPS power redundant power supply system according to claim 1, characterized in that: The UPS redundant power supply module also includes an emergency power supply module, which uses a supercapacitor group as a backup power supply. When all UPS units fail, the supercapacitor group will be put into operation within 1ms to maintain the power supply to the key control circuits of the hydrogen production equipment for no less than 30 seconds.

10. A safety explosion-proof electric contact pressure gauge and UPS power supply redundant power supply method, applied to the safety explosion-proof electric contact pressure gauge and UPS power supply redundant power supply system according to any one of claims 1 to 9, characterized in that: include S1: The safety explosion-proof electric contact pressure gauge module collects pressure data from hydrogen production equipment in real time, and adjusts the pressure relief valve opening and temperature compensation device power through the dynamic explosion-proof adjustment mechanism to ensure pressure measurement accuracy and explosion-proof performance; S2: The intelligent switching controller of the UPS redundant power supply module receives pressure data and mains and UPS status information, and calculates the optimal power supply strategy through the model predictive control algorithm; S3: The load distribution module dynamically adjusts the load current of each UPS unit according to the power supply strategy to achieve load balancing and fault isolation; S4: When the mains input is abnormal or the pressure exceeds the threshold, the intelligent switching controller triggers the fast switching mechanism to ensure power supply continuity; S5: The signal processing unit monitors the pressure signal characteristics in real time, identifies abnormal working conditions through the fault diagnosis module and triggers an early warning.

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