Resistance chain-based multi-point travel switch monitoring device and monitoring method

Abstract

The invention discloses a multi-point travel switch monitoring device and method based on a resistance chain, the device comprises a travel switch sensor, a signal excitation analysis system and a watertight cable, and the travel switch sensor comprises a travel switch fixing assembly, a travel switch moving assembly and a travel switch assembly support; a high-precision resistor with a specific resistance value and a magnetic reed switch are packaged in each travel switch fixing assembly, and the plurality of travel switch fixing assemblies are cascaded through a Y-shaped watertight cable to form a resistor chain; the signal excitation analysis system comprises a voltage excitation module, a voltage measurement module, a target resistor and travel switch state monitoring software. The signal excitation analysis system is connected with the first travel switch fixing assembly through a watertight connector and a watertight cable. Cascading serial monitoring of signals of multiple measuring points is achieved, the occupancy rate of watertight cable channels is reduced, the defects of redundant wiring, poor expansibility and the like of a traditional independent monitoring system are overcome, and a new technical approach is provided for state monitoring of the travel switch.

Description

Technical Field

[0001] The present invention relates to the technical field of travel switch monitoring devices, in particular to a multi-point travel switch monitoring device and a monitoring method based on a resistor chain. Background Art

[0002] Limit switches have many applications in the field of industrial control. They are mainly used to detect the position or motion range of objects and convert mechanical displacement signals into electrical signals. For example, monitoring the wedge position of the riser support structure is a typical application scenario of limit switches.

[0003] Monitoring the wedge position of the FPSO riser support structure is a core link in ensuring the safe operation of the marine oil and gas transportation system. As an important component of the riser support structure, the position of the wedge directly affects the stress distribution and structural integrity of the riser system. In the past, when controlling the hydraulic cylinder to move the locking wedge through the drive ring, the position of the locking wedge could only be observed by divers. This method is time-consuming and labor-intensive, and there are risks to personnel safety, high costs, and poor real-time performance. With the development of sensing and communication technology, in order to accurately determine the position of the locking wedge of the riser support structure, a travel switch sensor is generally used to monitor whether the locking wedge is locked in place. When the sensor detects that the wedge is not in place or there is an abnormality, the system issues an early warning, prompting the operator to take corresponding measures to avoid potential risks and losses. However, the riser support structure generally contains 8 to 10 locking wedges, and the position of each locking wedge needs to be monitored. If independent travel sensors are installed at each wedge position, 8 to 10 independent travel switch sensors are required. Each sensor requires a separate power supply and communication cable of at least 4 cores. This results in a large amount of wiring for a single riser support structure, significantly occupying limited watertight cable channel resources and affecting the integrated deployment of other monitoring systems. To reduce the number of watertight cable channels used and the complexity of wiring, a new riser support structure wedge position monitoring technology is needed. The FPSO riser support structure wedge position monitoring device and method based on a resistance chain travel switch has a unique cascade monitoring feature and can achieve a single-wire, 2-core transmission of signals from multiple measurement points. Taking 10 measurement points as an example, this can theoretically reduce the cable channel occupancy rate to more than 1 / 20 of that of traditional solutions, providing a new technical path to address existing technical bottlenecks. Summary of the Invention

[0004] In response to the shortcomings of the above-mentioned prior art, the applicant provides a multi-point travel switch monitoring device and monitoring method based on a resistance chain, thereby realizing cascade serial monitoring of signals from multiple measuring points, reducing the occupancy rate of watertight cable channels, overcoming the defects of traditional independent monitoring systems such as wiring redundancy and poor scalability, and providing a new technical approach for travel switch status monitoring.

[0005] The technical solutions adopted in the present invention are as follows:

[0006] A multi-point travel switch monitoring device based on a resistance chain, the monitoring device comprising a travel switch sensor, a signal excitation analysis system and a watertight cable, wherein the travel switch sensor is connected to the signal excitation analysis system via the watertight cable;

[0007] The travel switch sensor includes a travel switch fixing component, a travel switch moving component and a travel switch component support;

[0008] A single travel switch fixed component is encapsulated with a high-precision resistor and a reed switch. Multiple travel switch fixed components are cascaded through a watertight cable to form a resistor chain.

[0009] The signal excitation analysis system includes a voltage excitation module, a voltage measurement module, a target resistor, and travel switch status monitoring software. The signal excitation analysis system is connected to the first travel switch fixed component via a watertight connector and a watertight cable.

[0010] The watertight cables include multiple Y-type watertight cables and one type I watertight cable.

[0011] Its further technical solution is:

[0012] The surface of the travel switch moving component is encapsulated with a permanent magnet.

[0013] The travel switch assembly support is a right-angle structure.

[0014] A bottom plate is provided at the bottom of the travel switch component support.

[0015] The signal excitation analysis system is connected to the first travel switch fixing component through a watertight connector and a Y-shaped watertight cable.

[0016] The travel switch fixing assembly has a metal shell as an external protective structure, and a high-precision resistor and a reed switch are encapsulated inside the metal shell. The high-precision resistor and the reed switch are connected in parallel. A circuit board is also installed inside the metal shell. The circuit board is filled with quartz sand. The remaining space inside the metal shell is filled with epoxy resin. The tail of the travel switch fixing assembly is vulcanized and sealed with vulcanized rubber.

[0017] When the permanent magnet on the travel switch moving assembly approaches the reed switch inside the travel switch fixed assembly, the reed switch closes and the two ends of the high-precision resistor are short-circuited; when the permanent magnet on the travel switch moving assembly moves away from the reed switch inside the travel switch fixed assembly, the reed switch opens.

[0018] A monitoring method for a multi-point travel switch monitoring device based on a resistance chain,

[0019] The process includes the following:

[0020] The monitoring device is installed on the structure to be measured. When the travel switch moving component moves and contacts the travel switch fixed component, the high-precision resistors inside the travel switch fixed component are triggered to be in the conductive state, which further causes the resistance distribution of the resistor chain loop of the multi-point travel switch serial monitoring to change. A high-precision voltage excitation module is used to provide excitation voltage to the entire resistor chain. The voltage measurement module can realize the status monitoring of each travel switch by measuring the voltage division information of the target resistor. The voltage measurement value of the target resistor is:

[0021]

[0022] Where:

[0023] V in is the excitation voltage of the voltage excitation module,

[0024] R 11 is the target resistance value,

[0025] S i (i=1:10) is the state of the reed switch inside each travel switch fixing assembly. When the reed switch is closed, S i When it is 0, S i is 1, R i Fix the resistance value of the high-precision resistor inside each travel switch assembly;

[0026] To ensure that the operating current in the resistor chain is within the range allowed by the voltage excitation module, the resistance of the target resistor R11 should be large enough. The minimum resistance of R11 should be greater than or equal to:

[0027]

[0028] Where:

[0029] V in is the excitation voltage of the voltage excitation module,

[0030] I max The maximum operating current allowed by the voltage excitation module.

[0031] The total resistance of the resistor chain should be unique under each switch state combination. For the 10 travel switches K1 to K10, there are 1024 switch state combinations in the resistor chain. To ensure that the total resistance of the resistor chain under each of the 1024 switch state combinations is different and that the resistance matching has a certain regularity, the resistance values ​​of K1 to K10 need to be designed according to a geometric series, that is:

[0032] R i =R min r i-1 (r>1,i=1:10)

[0033] Where:

[0034] R min is the incremental change in resistance of the resistor chain,

[0035] r is the common ratio.

[0036] The beneficial effects of the present invention are as follows:

[0037] The present invention has a compact and reasonable structure and is easy to operate. Through the design of a unique monitoring device, the travel switch sensor includes a travel switch fixed component and a travel switch movable component. The travel switch fixed component is encapsulated with a high-precision resistor and a reed switch. When the travel switch movable component approaches the travel switch fixed component, the reed switch is closed and the two ends of the high-precision resistor are short-circuited. The travel switch sensors are cascaded using a watertight cable to form a resistor chain and connected to a signal excitation and analysis system. By reasonably matching the resistance value of the resistor chain, the status of each travel switch can be obtained in real time.

[0038] At the same time, the present invention also includes the following advantages:

[0039] (1) The travel switch fixing assembly is only equipped with a single-line 2-core watertight cable. Based on the Y-type cable and a conventional direct-connect cable wiring method, a resistance chain travel switch sensor is formed, which significantly reduces the umbilical cable channel occupancy rate required by the system. Taking the 10 measurement point signals required for a single set of riser support structure as an example, the cable channel occupancy rate can be reduced to more than 1 / 20 of the traditional solution;

[0040] (2) The system uses a reed switch as a sensitive element. Due to its passive characteristics, the travel switch sensor formed has the characteristics of being completely contactless, fully sealed, and resistant to media interference. In addition, it can be directly connected in parallel with a high-precision resistor to achieve short-circuiting in the design and integrated manufacturing of a multi-point travel switch serial monitoring system, and has high reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 It is a schematic diagram of the overall structural installation and wiring of the present invention.

[0042] Figure 2 Schematic diagram of the resistor chain state change principle of the present invention.

[0043] Figure 3 This is a schematic diagram of the system wiring of the present invention.

[0044] Figure 4 This is a schematic diagram of the package of the travel switch fixing assembly of the present invention.

[0045] Among them: 100, monitoring device;

[0046] 1. Travel switch sensor;

[0047] 101. Travel switch fixing assembly;

[0048] 1011. Metal housing; 1012. High-precision resistor; 1013. Reed switch; 1014. Circuit board; 1015. Quartz sand; 1016. Epoxy resin; 1017. Vulcanized rubber;

[0049] 102. Travel switch moving assembly;

[0050] 1021. Permanent magnet;

[0051] 103. Travel switch assembly support;

[0052] 2. Signal excitation analysis system;

[0053] 201. Voltage excitation module; 202. Voltage measurement module; 203. Target resistance; 204. Travel switch status monitoring software;

[0054] 3. Watertight cable;

[0055] 301. Y-type watertight cable; 302. Type I watertight cable. DETAILED DESCRIPTION

[0056] The specific embodiments of the present invention will be described below with reference to the accompanying drawings.

[0057] like Figures 1-4 As shown, the multi-point travel switch monitoring device based on the resistance chain of this embodiment includes a travel switch sensor 1, a signal excitation analysis system 2 and a watertight cable 3. The travel switch sensor 1 is connected to the signal excitation analysis system 2 via the watertight cable 3.

[0058] The travel switch sensor 1 includes a travel switch fixing component 101, a travel switch moving component 102 and a travel switch component support 103;

[0059] A single travel switch fixing assembly 101 contains a high-precision resistor 1012 and a reed switch 1013. Multiple travel switch fixing assemblies 101 are cascaded via a watertight cable 3 to form a resistor chain.

[0060] The signal excitation analysis system 2 includes a voltage excitation module 201, a voltage measurement module 202, a target resistance 203, and a travel switch state monitoring software 204. The signal excitation analysis system 2 is connected to the first travel switch fixing component 101 via a watertight connector and a watertight cable 3.

[0061] The watertight cable 3 includes a plurality of Y-shaped watertight cables 301 and a type I watertight cable 302 .

[0062] A permanent magnet 1021 is packaged on the surface of the travel switch moving component 102 .

[0063] The travel switch assembly support 103 is a right-angle structure.

[0064] A bottom plate is provided at the bottom of the travel switch assembly support 103 .

[0065] like Figures 1-4 As shown, the specific structure and functions of a multi-point travel switch monitoring device based on a resistor chain in this embodiment are as follows:

[0066] The monitoring device 100 mainly includes a travel switch sensor 1 , a signal excitation analysis system 2 and a watertight cable 3 .

[0067] The travel switch sensor 1 includes a travel switch fixing assembly 101 and a travel switch moving assembly 102. In this embodiment, the travel switch moving assembly 102 can be mounted on a roller shaft of the riser support structure, while the travel switch fixing assembly 101 can be bolted to a travel switch assembly support 103, which is welded or secured to the riser support structure using fasteners.

[0068] Among them, the signal excitation analysis system 2 includes a voltage excitation module 201, a voltage measurement module 202, a target resistance 203 and a travel switch status monitoring software 204. The signal excitation analysis system 2 is connected to the first travel switch fixing component 101 through a watertight connector and a Y-shaped watertight cable 301.

[0069] The watertight cable 3 includes a plurality of Y-shaped watertight cables 301 and a type I watertight cable 302 .

[0070] A permanent magnet 1021 is encapsulated on the surface of the travel switch moving component 102 so as to induce the sensitive element inside the travel switch fixed component 101 .

[0071] like Figure 4 As shown, the travel switch fixed component 101 has a metal shell 1011 as an external protective structure, and a high-precision resistor 1012 and a reed switch 1013 are encapsulated inside. The high-precision resistor 1012 and the reed switch 1013 are connected in parallel. When the permanent magnet 1021 located on the travel switch moving component 102 approaches the reed switch 1013 inside the travel switch fixed component 101, the reed switch 1013 is closed and the two ends of the high-precision resistor 1012 are short-circuited; when the permanent magnet 1021 located on the travel switch moving component 102 is away from the reed switch 1013 inside the travel switch fixed component 101, the reed switch 1013 is disconnected.

[0072] The internal packaging steps of the travel switch fixing assembly 101 are as follows:

[0073] a) Complete the printing of the internal circuit board 1014 of the travel switch, which is used to place the required high-precision resistor 1012 and reed switch 1013. The high-precision resistor 1012 and reed switch 1013 are connected in parallel;

[0074] b) Use a two-core Y-type cable or a type I cable to connect the two ends of the reed switch 1013 on the circuit board 1014, place the circuit board 1014 inside the metal structure of the limit switch, and fill the area around the circuit board 1014 with quartz sand 1015;

[0075] c) Use epoxy resin 1016 to fill the remaining space inside the limit switch structure to fix the cable;

[0076] d) Use vulcanized rubber 1017 to vulcanize and seal the tail of the travel switch structure and the cable to form a single travel switch fixing component 101.

[0077] like Figure 3 As shown, multiple groups of high-precision resistors 1012 inside the travel switch fixing components 101 and the target resistor 203 in the signal excitation analysis system 2 are connected in series through multiple Y-type watertight cables 301 and one type I watertight cable 302 to form a travel switch sensor 1 based on a resistor chain.

[0078] like Figure 1 Combine Figure 2 As shown, the working principle of this embodiment is as follows:

[0079] Because a high-precision resistor 1012 with a certain resistance value is encapsulated inside the travel switch fixed component 101, the travel switch moving component 102 is installed on the riser support structure and will move up and down as the drive ring of the riser support structure rotates. When the travel switch moving component 102 moves and contacts the travel switch fixed component 101, it triggers the high-precision resistor 1012 inside the travel switch fixed component 101 to be in a conductive state, which further causes the resistance distribution of the resistance chain loop of the serial monitoring of the multi-point travel switch to change. The high-precision voltage excitation module 201 is used to provide an excitation voltage to the entire resistor chain, and the voltage measurement module 202 can realize the status monitoring of each travel switch by measuring the voltage division information of the target resistor 203.

[0080] The voltage measurement across the target resistor is:

[0081]

[0082] Where: V in is the excitation voltage of the voltage excitation module, R 11 is the target resistance value, S i (i=1:10) is the state of the reed switch inside each travel switch fixing assembly. When the reed switch is closed, S iWhen it is 0, S i is 1, R i Fix the resistance value of the high-precision resistor inside each travel switch component.

[0083] To ensure that the operating current in the resistor chain is within the range allowed by the voltage excitation module, the resistance of the target resistor R11 should be large enough. The minimum resistance of R11 should not be less than:

[0084]

[0085] Where: V in is the excitation voltage of the voltage excitation module, I max The maximum operating current allowed by the voltage excitation module.

[0086] To achieve the measurement target, the voltage measurement value V of the target resistor out The minimum measured voltage difference under each switch state combination is not less than the voltage measurement error of the voltage measurement module.

[0087] The total resistance of the resistor chain should be unique under each switch state combination. For the 10 travel switches K1 to K10, there are 1024 switch state combinations in the resistor chain. To ensure that the total resistance of the resistor chain under each of the 1024 switch state combinations is different and that the resistance matching has a certain regularity, the resistance values ​​of K1 to K10 need to be designed according to a geometric series, that is:

[0088] R i =R min r i-1 (r>1,i=1:10)

[0089] Where: R min is the incremental change in resistance of the resistor chain, and r is the common ratio.

[0090] In general, the typical resistance values ​​of each travel switch are as follows: R1=1KΩ, R2=2KΩ, R3=4KΩ, R4=8KΩ, R5=16KΩ, R6=32KΩ, R7=64KΩ, R8=128KΩ, R9=256KΩ, R10=512KΩ. Under this resistance matching state, the measurement resolution of the entire loop resistance must be less than 1KΩ, which translates to the selection accuracy of the high-precision resistors used in each travel switch being no less than 0.01%.

[0091] When the resistance value inside the travel switch fixed component cannot be obtained by a single resistor, it is allowed to use multiple high-precision resistors in series to obtain the required resistance value.

[0092] It should be noted that the number of travel switches in this embodiment is not limited to the number in the above embodiments and the accompanying drawings, and can be increased or decreased as appropriate.

[0093] The above description is an explanation of the present invention, not a limitation of the present invention. The scope of the present invention is defined in the claims. Any modifications may be made within the scope of protection of the present invention.

Claims

1. A multi-point travel switch monitoring device based on a resistor chain, characterized by: The monitoring device (100) comprises a travel switch sensor (1), a signal excitation analysis system (2) and a watertight cable (3), wherein the travel switch sensor (1) is connected to the signal excitation analysis system (2) via the watertight cable (3); The travel switch sensor (1) comprises a travel switch fixing assembly (101), a travel switch moving assembly (102) and a travel switch assembly support (103); A single travel switch fixing assembly (101) encapsulates a high-precision resistor (1012) and a reed switch (1013) therein, and multiple travel switch fixing assemblies (101) are cascaded via a watertight cable (3) to form a resistor chain; The signal excitation analysis system (2) includes a voltage excitation module (201), a voltage measurement module (202), a target resistance (203) and a travel switch state monitoring software (204). The signal excitation analysis system (2) is connected to the first travel switch fixing component (101) via a watertight connector and a watertight cable (3); The watertight cable (3) comprises a plurality of Y-shaped watertight cables (301) and a type I watertight cable (302).

2. A multi-point travel switch monitoring device based on a resistor chain as claimed in claim 1, characterized in that: A permanent magnet (1021) is encapsulated on the surface of the travel switch moving component (102).

3. A multi-point travel switch monitoring device based on a resistor chain as claimed in claim 2, characterized in that: The travel switch assembly support (103) is in a right-angled structure.

4. A multi-point travel switch monitoring device based on a resistor chain as claimed in claim 3, characterized in that: A bottom plate is provided at the bottom of the travel switch assembly support (103).

5. The multi-point travel switch monitoring device based on a resistor chain according to claim 4, characterized in that: The signal excitation analysis system (2) is connected to the first travel switch fixing assembly (101) via a watertight connector and a Y-shaped watertight cable (301).

6. A multi-point travel switch monitoring device based on a resistor chain as claimed in claim 5, characterized in that: The travel switch fixing assembly (101) comprises a metal shell (1011) as an external protective structure. A high-precision resistor (1012) and a reed switch (1013) are encapsulated inside the metal shell (1011). The high-precision resistor (1012) and the reed switch (1013) are connected in parallel. A circuit board (1014) is also installed inside the metal shell (1011). The circuit board (1014) is filled with quartz sand (1015). The remaining space inside the metal shell (1011) is filled with epoxy resin (1016). The tail of the travel switch fixing assembly (101) is vulcanized and sealed using vulcanized rubber (1017).

7. A multi-point travel switch monitoring device based on a resistor chain as claimed in claim 6, characterized in that: When the permanent magnet (1021) on the travel switch moving component (102) approaches the reed switch (1013) inside the travel switch fixed component (101), the reed switch (1013) is closed and the two ends of the high-precision resistor (1012) are short-circuited; when the permanent magnet (1021) on the travel switch moving component (102) moves away from the reed switch (1013) inside the travel switch fixed component (101), the reed switch (1013) is opened.

8. A monitoring method for a multi-point travel switch monitoring device based on a resistor chain according to claim 7, characterized in that: The process includes the following: The monitoring device (100) is installed on the structure to be tested. When the travel switch moving component (102) moves and contacts the travel switch fixing component (101), the two ends of the high-precision resistor (1012) inside the travel switch fixing component (101) are triggered to be in a conductive state, which further causes the resistance distribution of the resistor chain loop of the multi-point travel switch serial monitoring to change. A high-precision voltage excitation module (201) is used to provide an excitation voltage to the entire resistor chain. The voltage measurement module (202) can realize the state monitoring of each travel switch by measuring the voltage division information of the target resistor (203). The voltage measurement value of the target resistor is: Where: V in is the excitation voltage of the voltage excitation module, R 11 is the target resistance value, S i (i=1:10) is the state of the reed switch inside each travel switch fixing assembly. When the reed switch is closed, S i When it is 0, S i is 1, R i Fix the resistance value of the high-precision resistor inside each travel switch assembly; To ensure that the operating current in the resistor chain is within the range allowed by the voltage excitation module, the resistance of the target resistor R11 should be large enough. The minimum resistance of R11 should be greater than or equal to: Where: V in is the excitation voltage of the voltage excitation module, I max The maximum operating current allowed by the voltage excitation module.

9. The monitoring method of the multi-point travel switch monitoring device based on the resistor chain according to claim 8, characterized in that: The total resistance of the resistor chain should be unique under each switch state combination. For the 10 travel switches K1 to K10, there are 1024 switch state combinations in the resistor chain. To ensure that the total resistance of the resistor chain under each of the 1024 switch state combinations is different and that the resistance matching has a certain regularity, the resistance values ​​of K1 to K10 need to be designed according to a geometric series, that is: R i =R min r i-1 (r>1,i=1:10) Where: R min is the incremental change in resistance of the resistor chain, r is the common ratio.

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