Industrial field distributed IO terminal of explosion-proof box and control system of industrial field distributed IO terminal

Abstract

The invention relates to the technical field of industrial field control, in particular to an industrial field distributed IO terminal of an explosion-proof box and a control system of the industrial field distributed IO terminal, an internal IO module in the IO terminal is used for converting a control signal into an electric signal of control equipment, and a DI acquisition module is used for acquiring operation characteristic parameter information of a plurality of reaction kettles in an industrial field target area; the DO control module is used for analyzing the operation characteristic parameter information of the plurality of reaction kettles so as to output a control signal; the redundant power supply is used for supplying power to the PCB and the internal IO module; the redundant communication interface is used for controlling a signal of the internal IO module; the wiring terminal is used for electrically connecting a controlled actuator; and the explosion-proof box is used for preventing explosion and signal interference of the IO terminal. Wherein the DI and the DO are detachable, the acquisition module further comprises an AI, and the control module further comprises an AO. According to the invention, cables are saved, the redundant power supply and the redundant communication interface are arranged, and the efficiency of the IO terminal is improved.

Description

Technical Field

[0001] This invention relates to the field of industrial field control technology, and in particular to an industrial field distributed I / O terminal and its control system for an explosion-proof enclosure. Background Technology

[0002] As safety requirements in industrial settings become increasingly stringent, particularly in explosion-proof areas of chemical and other industries, monitoring equipment must not only possess high safety standards (such as explosion-proof certification) but also provide early warnings and intelligent control of the operational status of critical process equipment. However, existing distributed I / O terminals offer limited functionality, mostly performing simple signal acquisition and conversion, lacking localized intelligent data analysis capabilities, and unable to dynamically adjust monitoring strategies based on real-time equipment health status. Furthermore, power and communication links commonly suffer from single-point-of-failure risks, making it difficult to meet the stringent requirements of modern process industries for high reliability, predictive maintenance, and intrinsic safety.

[0003] Chinese Patent Publication No. CN114326529A discloses an industrial automation control system with a remote I / O terminal module. This invention applies to the technical field of multi-machine collaborative industrial automation control systems between remote I / O master and slave devices. It provides an industrial automation control system with a remote I / O terminal module. The master device in this system has a built-in cascading communication interface, which allows for cascading with other masters, eliminating the need for additional switch configurations and connections. This makes connection and use more convenient and reduces costs. A bus control communication interface module connects to the slave device for data exchange, enabling communication with the slave device. The master device also has an I / O interface module. When the I / O interface needs to perform corresponding functions, no additional expansion modules are required, further improving the ease of use of the master device and reducing its operating costs.

[0004] Therefore, it is evident that the existing technology has the following problems: There is an explosion risk in the industrial site, and IO terminal failure may lead to an accident. The safe operation of the equipment in hazardous environments has not been considered. There are problems with insufficient power supply to the I / O terminal and unstable communication signal; redundant power supply and redundant communication have not been considered. Traditional I / O systems lack the ability to analyze and adaptively adjust the operating status of devices in real time. Summary of the Invention

[0005] Therefore, the present invention provides an industrial field distributed I / O terminal and its control system for an explosion-proof enclosure, in order to overcome the problem that the existing technology has the risk of explosion in industrial fields, and the I / O terminal failure may lead to accidents, and does not consider the safe operation of equipment in dangerous environments; There are problems with insufficient power supply to the I / O terminal and unstable communication signal; redundant power supply and redundant communication have not been considered. Traditional I / O systems lack the ability to analyze and adaptively adjust the operating status of devices in real time.

[0006] To achieve the above objectives, the present invention provides an industrial field distributed I / O terminal for an explosion-proof enclosure, comprising: The internal I / O module includes several DI acquisition modules and DO control modules, used to convert internal control signals into electrical signals for controlling the device. The DI acquisition module is used to acquire the operating characteristic parameter information of several reactors in the target area of ​​the industrial site; The DO control module, connected to the DI acquisition module, is used to analyze the operating characteristic parameters of several reactors to output control signals. The DO control module includes a data analysis unit, a risk prediction unit, a standard evaluation unit, and a power control unit. The data analysis unit is connected to the DI acquisition module and is used to analyze the operating characteristic values ​​of the reactors based on the operating characteristic parameter information of each reactor. The risk prediction unit is connected to the data analysis unit and is used to determine the control algorithm execution frequency of the operating characteristic parameter information of each reactor based on the operating characteristic characterization value of each reactor. The standard evaluation unit, which is connected to the risk prediction unit, is used to determine whether the operation of the IO terminal meets the standard based on the execution frequency of the control algorithm based on the operating characteristic parameter information of several reactors. A redundant power supply is provided to power the PCB board and the internal I / O module. A redundant communication interface is provided for controlling the signals of the internal I / O module. Terminal blocks are used for electrical connections to sensors and actuators used to control target areas within the workshop. An explosion-proof enclosure is installed outside the I / O terminal to protect the I / O terminal from explosion, corrosion, and signal interference. The operational characteristic parameters include: liquid temperature inside the reactor, inlet temperature of the reactor jacket, outlet temperature of the reactor jacket, internal pressure of the reactor, and outlet pressure of the reactor jacket.

[0007] Furthermore, the data analysis unit determines the operating characteristic value of each reactor by summing the first reactor operating characteristic parameter, the second reactor operating characteristic parameter, the third reactor operating characteristic parameter, the fourth reactor operating characteristic parameter, and the fifth reactor operating characteristic parameter. The operating characteristic parameters of the first, second, third, fourth, and fifth reactors are calculated using the liquid temperature inside each reactor, the inlet temperature of the reactor jacket, the outlet temperature of the reactor jacket, the internal pressure of the reactor, and the outlet pressure of the reactor jacket, respectively.

[0008] Furthermore, the risk prediction unit is used to determine that each reactor is in an operational risk cycle based on the condition that the operating characteristic characterization value of each reactor is less than or equal to a predetermined operating characteristic characterization value threshold.

[0009] Furthermore, the risk prediction unit is used to determine the increase in the execution frequency of the control algorithm for the operating characteristic parameter information of each reactor based on the ratio of the operating characteristic characterization value of the reactor to a predetermined operating characteristic characterization value threshold when each reactor is in an operating risk cycle.

[0010] Furthermore, the standard evaluation unit determines whether the operation of the IO terminal conforms to the standard by using a control algorithm based on the operating characteristic parameter information of the reactor with a frequency greater than or equal to a preset frequency threshold. If the number of controlled reactors exceeds a preset threshold, the IO terminal is deemed to be operating incorrectly.

[0011] Furthermore, the explosion-proof enclosure is made of 304 stainless steel with a brushed surface; The explosion-proof marking of the explosion-proof enclosure is Exd IIBT6 Gb.

[0012] Furthermore, the DI acquisition module and the DO control module are detachable, the acquisition module also includes a detachable AI acquisition module, and the control module also includes a detachable AO control module.

[0013] Furthermore, the corrosion resistance rating of the explosion-proof enclosure is F2; The explosion-proof enclosure has an IP65 protection rating.

[0014] Furthermore, it also includes wiring rules for industrial sites based on the distributed I / O terminal, including: Place several of the aforementioned IO terminals in the target area of ​​the industrial site; Several cables are laid out based on the wiring terminals of each IO terminal to connect several sensors that collect information on the operating characteristic parameters of the reactor. Two communication cables are laid to connect the central control room in the industrial site based on the redundant communication interfaces of each IO terminal. The redundant communication interface includes two communication interfaces.

[0015] Furthermore, the present invention also provides a control system for an industrial field distributed I / O terminal of an explosion-proof enclosure, comprising, The DI acquisition module is used to collect operational characteristic parameter information of several reactors in the target area of ​​the industrial site; The DO control module, connected to the DI acquisition module, is used to analyze the operating characteristic parameters of several reactors and output control signals; including, The data analysis unit, which is connected to the DI acquisition module, is used to analyze the operating characteristic values ​​of the reactors based on the operating characteristic parameter information of each reactor. A risk prediction unit, connected to the data analysis unit, is used to determine the execution frequency of the control algorithm based on the operating characteristic characterization values ​​of each reactor to determine the operating characteristic parameter information of each reactor. A standard evaluation unit, which is connected to the risk prediction unit, is used to determine whether the operation of the IO terminal meets the standard based on the execution frequency of the control algorithm based on the operating characteristic parameter information of several reactors. The power control unit, which is connected to the risk prediction unit and the standard evaluation unit, is used to determine the control algorithm execution frequency threshold for adjusting the reactor's operating characteristic parameter information when the IO terminal does not meet the standard, or to determine to start the redundant power supply.

[0016] Compared with existing technologies, the advantages of this invention are as follows: This invention provides an industrial field distributed I / O terminal and its control system in an explosion-proof enclosure. By integrating internal I / O modules, including DI and DO, redundant power supplies, and redundant communication interfaces, into a certified explosion-proof enclosure, it fundamentally solves the pain point of traditional systems requiring the laying of a large number of cables to remote cabinets, greatly saving the cost of cables and cable trays, as well as construction time and expenses, and reducing the floor space occupied by the central cabinet. Secondly, its level of intelligence far exceeds that of traditional I / O terminals that only perform signal conversion. Through the four units embedded in the DO control module, including data analysis, risk prediction, standard assessment, and power control, it can calculate the operating status of the reactor in real time based on the most critical operating parameters of the reactor—temperature and pressure—and dynamically adjust the monitoring frequency to respond to potential risks. Finally, the dual redundancy design—combining power supply and communication with explosion-proof protection—ensures the system's ultimate reliability and safety in harsh and dangerous industrial environments, avoiding production interruptions or safety accidents caused by single-point failures. This provides critical infrastructure support for the intelligent upgrading of process industries and significantly improves the operating efficiency of the I / O terminal and its control system.

[0017] In particular, by calculating operational characteristic values ​​based on the reactor's operational characteristic parameters using the data analysis unit, a scientifically sound multi-parameter fusion method is provided, which can objectively reflect the actual impact of each parameter on the reactor's safety status. Temperature and internal pressure are the two most critical and direct parameters in reactor operation. Integrating them into a single characteristic value provides a unified and quantitative indicator for subsequent risk prediction and decision-making. The simple yet effective "summation" operation reduces system computational complexity and improves response speed, making it highly suitable for industrial edge computing scenarios requiring real-time processing. Comprehensive evaluation makes the system's judgment of the reactor's status more comprehensive and accurate. While a single parameter exceeding the standard may not be sufficient to determine risk, the weighted sum of two simultaneously abnormal parameters can more reliably trigger early warnings, reducing the probability of false alarms and missed alarms.

[0018] In particular, by comparing the calculated operational characteristic values ​​with a predetermined threshold, a risk period is identified when the value is less than or equal to the threshold. This allows the system to automatically and objectively identify which reactors are entering or about to enter abnormal or dangerous states. This enables precise guidance of monitoring to high-risk equipment, thereby achieving optimized resource allocation and predictive maintenance. This is a crucial step from preventative to predictive maintenance, effectively preventing unexpected downtime, production losses, and even safety accidents caused by equipment failures, thus improving the stability and safety of the entire production process. The ratio of the operational characteristic value to the threshold quantifies the risk level of the reactor, proportionally determining the increase in the execution frequency of the control algorithm. The higher the risk of the equipment, the smaller the ratio, meaning the actual value is far below the safety threshold, and the more intensive the monitoring. Dynamically adjusting the strategy offers two major advantages: first, it optimizes system resource allocation, prioritizing limited computing and communication resources for the highest-risk equipment, avoiding excessive system load and resource waste caused by indiscriminate high-frequency data acquisition; second, it provides more continuous and detailed risk trend data, which is extremely valuable for analyzing the failure evolution process and locating the root cause, making monitoring more intelligent and efficient.

[0019] In particular, by statistically analyzing the number of reactors whose control algorithm execution frequency exceeds the limit and comparing it to a threshold number, it can be determined whether the overall workload of the current IO terminal has approached or exceeded its design limit for normal processing capacity. If too many devices exceed the limit, it indicates that the on-site operating conditions have generally deteriorated or the system settings are unreasonable. Adjustments to the IO terminals can then be made to prevent the entire distributed node from being paralyzed due to the accumulation of local problems. When it is found that the control algorithm execution frequency of most reactors only slightly exceeds the limit, and the difference is small compared to the preset difference threshold, the system judges that the problem may stem from the initially set control algorithm execution frequency threshold being too conservative, rather than a drastic deterioration of the on-site operating conditions. In this case, by automatically adjusting this frequency threshold, the normal standard is actually relaxed, allowing the system to return to a standard-compliant state without activating redundant power supplies. The advantage of this approach is that it avoids overreaction, prioritizes software parameter adjustments to resolve conflicts, saves hardware redundancy resources, and extends the lifespan of redundant power supplies. It reflects the flexibility and intelligence of the system design, enabling it to self-optimize and adjust strategy parameters according to actual operating conditions, maintaining efficient and stable operation. When a significant number of reactors experience control algorithm execution frequency demands that far exceed the normal range, with large discrepancies and threshold values, it indicates extremely severe on-site conditions requiring full-scale monitoring by the I / O terminal. At this point, simple parameter adjustments are insufficient, necessitating the use of redundant hardware resources. Activating redundant power supplies provides absolute, robust power assurance, ensuring that internal I / O modules, processors, and communication modules receive sufficient and stable power even under extremely high data acquisition and processing loads, preventing fatal failures such as data acquisition failures, system restarts, or card damage due to insufficient power.

[0020] In particular, by integrating all modules of the entire control system into the explosion-proof enclosure and specifying the materials, processes, and certification levels of the enclosure, the safety of equipment in industrial sites, especially in hazardous areas, is improved. This enables the equipment to withstand harsh conditions such as corrosion, humidity, and dust in chemical environments, ensuring long-term reliable operation of the equipment. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of an industrial field distributed I / O terminal based on an explosion-proof box according to an embodiment of the present invention; Figure 2 A comparison diagram of traditional cabling methods and I / O terminal-based cabling methods in industrial settings according to embodiments of the present invention; Figure 3 The present invention provides a logic determination diagram for determining whether each reactor is in an operational risk period based on the operational characteristic parameter information of each reactor. Figure 4The embodiment of the present invention uses a control algorithm based on the operating characteristic parameter information of the reactor to determine whether the operation of the IO terminal conforms to the standard by determining the number of reactors under control when the execution frequency is greater than or equal to a preset frequency threshold.

[0022] in, Figure 1 The correspondence between the reference numerals and component names in the attached drawings is as follows: 1-Explosion-proof enclosure, 2-DI acquisition module, 3-DO control module, 4-Terminal block, 5-Redundant power supply, 6-Redundant communication interface. Detailed Implementation

[0023] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0024] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0025] Please see Figure 1 , Figure 2 , Figure 3 as well as Figure 4 As shown, it is a structural schematic diagram of the industrial field distributed IO terminal based on the explosion-proof box according to an embodiment of the present invention; a comparison diagram of the traditional wiring method and the IO terminal-based wiring method in the industrial field according to an embodiment of the present invention; a logic determination diagram of determining whether each reactor is in an operational risk cycle based on the operating characteristic parameter information of each reactor according to an embodiment of the present invention; and a logic determination diagram of determining whether the operation of the IO terminal conforms to the standard based on the number of reactors whose control algorithm execution frequency is greater than or equal to a preset frequency threshold.

[0026] This invention provides an industrial field distributed I / O terminal for an explosion-proof enclosure, comprising: The internal I / O module includes several DI acquisition modules and DO control modules, used to convert internal control signals into electrical signals for controlling the device. The DI acquisition module 2 is used to acquire the operating characteristic parameter information of several reactors in the target area of ​​the industrial site; The DO control module 3, connected to the DI acquisition module, is used to analyze the operating characteristic parameters of several reactors and output control signals. The DO control module includes a data analysis unit, a risk prediction unit, a standard evaluation unit, and a power control unit. The data analysis unit is connected to the DI acquisition module and is used to analyze the operating characteristic values ​​of the reactors based on the operating characteristic parameter information of each reactor. The risk prediction unit is connected to the data analysis unit and is used to determine the control algorithm execution frequency of the operating characteristic parameter information of each reactor based on the operating characteristic characterization value of each reactor. The standard evaluation unit, which is connected to the risk prediction unit, is used to determine whether the operation of the IO terminal meets the standard based on the execution frequency of the control algorithm based on the operating characteristic parameter information of several reactors. The power control unit, which is connected to the risk prediction unit and the standard evaluation unit, is used to determine, when the IO terminal does not operate in accordance with the standard, to adjust the control algorithm execution frequency threshold based on the difference between the control algorithm execution frequency and the predetermined control algorithm execution frequency threshold for the operating characteristic parameter information of several reactors, or to determine to start the redundant power supply. Redundant power supply 5 is used to power the PCB board and the internal IO module; Redundant communication interface 6, which is used to control the signals of the internal IO module; Terminal 4 is used for electrical connection to actuators controlling target areas within the workshop; Explosion-proof enclosure 1, which is installed outside the IO terminal, is used for explosion protection and signal interference protection of the IO terminal; The operational characteristic parameters include: liquid temperature inside the reactor and internal pressure inside the reactor.

[0027] By integrating internal I / O modules, DI and DO, redundant power supplies, and redundant communication interfaces into a certified explosion-proof enclosure, this system fundamentally solves the pain point of traditional systems requiring extensive cabling to remote cabinets. This significantly reduces the cost of cables and cable trays, as well as construction time and expenses, and minimizes the footprint of the central cabinet. Secondly, its level of intelligence far surpasses traditional I / O terminals that only perform signal conversion. Through the four units embedded in the DO control module—data analysis, risk prediction, standard assessment, and power control—it can calculate the reactor's operating status in real time based on its most critical operating parameters, temperature and pressure, and dynamically adjust the monitoring frequency to respond to potential risks. Finally, the dual redundancy design, combining power supply and communication with explosion-proof protection, ensures the system's extreme reliability and safety in harsh and hazardous industrial environments. This avoids production interruptions or safety accidents caused by single-point failures, providing crucial infrastructure support for the intelligent upgrading of process industries and significantly improving the operational efficiency of the I / O terminal and its control system.

[0028] In this embodiment, the redundant power supply 5 includes two 24V power supplies to support the normal operation of the internal I / O module.

[0029] By specifying the exact specifications of the redundant power supply, the beneficial effect is that it clarifies the reliability and compatibility of the implementation. A dual-power supply configuration means that when one power supply fails, the other can seamlessly take over the entire load, achieving N+1 redundancy and significantly improving the system's mean time between failures (MTBF).

[0030] Specifically, the data analysis unit determines the operating characteristic value of each reactor by summing the first reactor operating characteristic parameter, the second reactor operating characteristic parameter, the third reactor operating characteristic parameter, the fourth reactor operating characteristic parameter, and the fifth reactor operating characteristic parameter. The operating characteristic parameters of the first, second, third, fourth, and fifth reactors are calculated using the liquid temperature inside each reactor, the inlet temperature of the reactor jacket, the outlet temperature of the reactor jacket, the internal pressure of the reactor, and the outlet pressure of the reactor jacket, respectively.

[0031] In this embodiment, the temperature of the liquid inside each reactor is collected by a temperature sensor installed inside the reactor, and the signal is transmitted to the corresponding distributed I / O terminal; the pressure inside each reactor is collected by a pressure transmitter installed on the top of each reactor, and the signal is transmitted to the corresponding distributed I / O terminal.

[0032] In this embodiment, the process of analyzing the operational characteristic values ​​of each reactor based on its operational characteristic parameter information includes: The ratio of the maximum liquid temperature inside a single reactor within the current monitoring period to a preset liquid temperature threshold is determined as the first reactor operating characteristic parameter; the ratio of the maximum jacket inlet temperature of a single reactor within the current monitoring period to a preset jacket inlet temperature threshold is determined as the second reactor operating characteristic parameter; the ratio of the maximum jacket outlet temperature of a single reactor within the current monitoring period to a preset jacket outlet temperature threshold is determined as the third reactor operating characteristic parameter; the ratio of the maximum internal pressure of a single reactor within the current monitoring period to a preset internal pressure threshold is determined as the fourth reactor operating characteristic parameter; and the ratio of the maximum jacket outlet pressure of a single reactor within the current monitoring period to a preset jacket outlet pressure threshold is determined as the fifth reactor operating characteristic parameter. The sum of the first, second, third, fourth, and fifth reactor operating characteristic parameters is used to determine the corresponding reactor operating characteristic value.

[0033] In this embodiment, the threshold corresponding to the above-mentioned reactor operating characteristic parameters is obtained in advance and set as the 60th percentile of the reactor operating characteristic parameters under historical normal operating conditions.

[0034] By comparing calculated operational characteristic values ​​with a predetermined threshold, the system can automatically and objectively identify which reactors are entering or about to enter abnormal or dangerous states when a risk period is determined. This allows monitoring attention to be precisely directed to high-risk equipment, thereby achieving optimized resource allocation and predictive maintenance. This is a crucial step from preventative maintenance to predictive maintenance, effectively preventing unexpected downtime, production losses, and even safety accidents caused by equipment failures, thus improving the stability and safety of the entire production process.

[0035] Specifically, the risk prediction unit is used to determine that each reactor is in an operational risk cycle based on the condition that the operating characteristic characterization value of each reactor is less than or equal to a predetermined operating characteristic characterization value threshold.

[0036] In this embodiment, the threshold value of the running feature is obtained in advance, and preferably takes a value in the range of [2.02, 2.05].

[0037] By setting clear threshold values ​​for operational characteristics, a clear standard for risk cycle determination is provided. Setting the threshold slightly higher than the ideal value of 2.0 ensures the system's sensitivity to real risks while providing a certain degree of fault tolerance, avoiding false alarms caused by normal parameter fluctuations.

[0038] The risk level of the reactor is quantified by the ratio of the characteristic value to the threshold, which proportionally determines the increase in the execution frequency of the control algorithm. Equipment with higher risk requires more intensive monitoring. This dynamic adjustment strategy offers two major advantages: first, it optimizes system resource allocation, prioritizing limited computing and communication resources for the highest-risk equipment, avoiding excessive system load and resource waste caused by indiscriminate high-frequency data acquisition; second, it provides more continuous and detailed risk trend data, which is extremely valuable for analyzing the failure evolution process and locating the root cause, making monitoring more intelligent and efficient.

[0039] Specifically, the risk prediction unit is used to determine the increase in the execution frequency of the control algorithm for the operating characteristic parameter information of each reactor based on the ratio of the operating characteristic characterization value of the reactor to a predetermined operating characteristic characterization value threshold when each reactor is in an operating risk cycle.

[0040] Understandably, the larger the ratio of the operating characteristic value of the reactor to the predetermined operating characteristic value threshold, the further it deviates from the normal value and the higher the risk. Therefore, the frequency of the control algorithm execution also increases by a larger factor.

[0041] By statistically analyzing the number of reactors requiring high-frequency monitoring and comparing it to a threshold, it can be determined whether the overall workload of the current I / O terminals is approaching or exceeding their design limits for normal processing capacity. If too many devices exceed these limits, it indicates a general deterioration in on-site conditions or an unreasonable system configuration. Adjustments to the I / O terminals can then be made to prevent the accumulation of localized problems from paralyzing the entire distributed node.

[0042] Specifically, the standard evaluation unit determines whether the operation of the IO terminal conforms to the standard by using a control algorithm based on the operating characteristic parameter information of the reactor with a frequency greater than or equal to a preset frequency threshold and a number of controlled reactors. If the number of controlled reactors exceeds a preset threshold, the IO terminal is deemed to be operating incorrectly.

[0043] In this embodiment, the frequency threshold is set to the 90th percentile of the execution frequency of the single-channel security control algorithm allowed by the system within the historical period. The quantity threshold is set to the 90th percentile of the number of over-limit devices that the system can stably handle within the historical period.

[0044] By statistically analyzing the number of reactors requiring high-frequency monitoring and comparing it to a threshold, it can be determined whether the overall workload of the current I / O terminals is approaching or exceeding their design limits for normal processing capacity. If too many devices exceed these limits, it indicates a general deterioration in on-site conditions or an unreasonable system configuration. Adjustments to the I / O terminals can then be made to prevent the accumulation of localized problems from paralyzing the entire distributed node.

[0045] Specifically, the power control unit is used to determine whether to adjust the control algorithm execution frequency threshold based on the operating characteristic parameter information of the reactor when the IO terminal does not operate in accordance with the standard, based on the number of reactors controlled by the difference between the control algorithm execution frequency based on the reactor's operating characteristic parameter information and the predetermined data control algorithm execution frequency threshold is less than a preset difference threshold. If the number of controlled reactors exceeds a preset threshold, the frequency threshold for the control algorithm based on the reactor's operating characteristic parameters will be adjusted.

[0046] In this embodiment, the difference threshold is set to twice the standard deviation of the execution frequency of all channel control algorithms within the historical period. It can be understood that the difference threshold is predetermined, specifically the maximum difference value within the month prior to system operation. The quantity threshold is set to the 90th percentile of the number of controlled reactors whose difference is less than the preset difference threshold within the historical period. When the number of controlled reactors exceeds the preset quantity threshold, the average execution frequency of the control algorithms for the current operating characteristic parameter information of several reactors is set as the execution frequency of the control algorithms for the new operating characteristic parameter information of the reactors.

[0047] Specifically, the power control unit is used to determine whether to start the redundant power supply when the IO terminal does not operate in accordance with the standard, based on the difference between the control algorithm execution frequency of the reactor and the predetermined data control algorithm execution frequency threshold, which is greater than or equal to a preset difference threshold, for the number of reactors under control. If the number of controlled reactors is greater than a preset threshold, the control algorithm execution frequency threshold for the reactor's operating characteristic parameters is adjusted to start the redundant power supply.

[0048] The quantity threshold is set as the 90th percentile of the number of controlled over-limit reactors whose difference is greater than or equal to a preset difference threshold within a historical period.

[0049] Understandably, when it's found that the control algorithm execution frequency of most reactors only slightly exceeds the limit, the system judges that the problem may stem from an overly conservative initial control algorithm execution frequency threshold, rather than a drastic deterioration of the on-site conditions. In this case, by automatically adjusting this frequency threshold, the system can return to a "compliant" state without activating redundant power supplies. This avoids overreaction, prioritizes software parameter adjustments to resolve conflicts, saves hardware redundancy resources, and extends the lifespan of redundant power supplies. It demonstrates the flexibility and intelligence of the system design, enabling it to self-optimize and adjust strategy parameters based on actual operating conditions, maintaining efficient and stable operation. When a significant number of reactors have control algorithm execution frequency requirements far exceeding the normal range, it indicates extremely severe on-site conditions, requiring full-scale monitoring by the I / O terminal. At this point, simple parameter adjustments are insufficient, and hardware redundancy resources must be utilized. Activating redundant power supplies provides absolute, rigid power assurance, ensuring that internal I / O modules, processors, and communication modules receive sufficient and stable power even under extremely high data acquisition and processing loads, preventing fatal failures such as data acquisition failures, system restarts, or card damage due to insufficient power.

[0050] Specifically, the explosion-proof box 1 is made of 304 stainless steel with a brushed surface and the natural color of stainless steel; The explosion-proof marking of the explosion-proof enclosure is Exd IIBT6 Gb; The explosion-proof enclosure has an IP65 protection rating. The corrosion resistance rating of the explosion-proof enclosure is F2.

[0051] By integrating all modules of the entire control system into the explosion-proof enclosure and specifying the materials, processes, and certification levels of the enclosure, the safety of equipment in industrial sites, especially in hazardous areas, is improved. This enables the equipment to withstand harsh conditions such as corrosion, humidity, and dust in chemical environments, ensuring long-term reliable operation of the equipment.

[0052] Specifically, it also includes wiring rules for industrial sites based on the distributed I / O terminal, including: Place several of the aforementioned IO terminals in the target area of ​​the industrial site; Several cables are laid out based on the wiring terminals of each IO terminal to connect several sensors that collect information on the operating characteristic parameters of the reactor. Based on the redundant communication interfaces of each IO terminal, two communication cables are laid to connect to the central control room of the industrial site. The redundant communication interface 6 includes two communication interfaces.

[0053] By providing specific implementation methods and deployment rules for the distributed I / O terminals, the terminals are placed nearby, sensor signals are accessed nearby, and the central control unit is connected via redundant communication cables. This deployment rule significantly reduces cable, cable tray, and construction costs, shortens the construction period, and reduces the space required between cabinets.

[0054] Specifically, the DI acquisition module and the DO control module are detachable, the acquisition module also includes a detachable AI acquisition module, and the control module also includes a detachable AO control module.

[0055] Understandably, the AI ​​or DI acquisition module and the AO or DO control module are combined according to the type of field instrument and the required signal type is selected. If a solenoid valve needs to be connected, DI and DO are used; if a regulating valve needs to be connected, AI and AO are used.

[0056] Specifically, it also includes the control system of the industrial field distributed I / O terminal of the explosion-proof enclosure, including, The DI acquisition module is used to collect operational characteristic parameter information of several reactors in the target area of ​​the industrial site; The DO control module, connected to the DI acquisition module, is used to analyze the operating characteristic parameters of several reactors and output control signals; including, The data analysis unit, which is connected to the DI acquisition module, is used to analyze the operating characteristic values ​​of the reactors based on the operating characteristic parameter information of each reactor. A risk prediction unit, connected to the data analysis unit, is used to determine the execution frequency of the control algorithm based on the operating characteristic characterization values ​​of each reactor to determine the operating characteristic parameter information of each reactor. A standard evaluation unit, which is connected to the risk prediction unit, is used to determine whether the operation of the IO terminal meets the standard based on the execution frequency of the control algorithm based on the operating characteristic parameter information of several reactors. The power control unit, which is connected to the risk prediction unit and the standard evaluation unit, is used to determine the control algorithm execution frequency threshold for adjusting the reactor's operating characteristic parameter information when the IO terminal does not meet the standard, or to determine to start the redundant power supply.

[0057] It is understandable that the software algorithm of the embodiment is fast and can be adaptively adjusted, and can automatically adjust the control algorithm parameters according to the changes in the parameters of the application site. The system of the embodiment has a self-diagnostic function.

[0058] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. An industrial field distributed I / O terminal for an explosion-proof enclosure, characterized in that, include: The internal I / O module includes several DI acquisition modules and DO control modules, used to convert internal control signals into electrical signals for controlling the device. The DI acquisition module is used to acquire the operating characteristic parameter information of several reactors in the target area of ​​the industrial site; The DO control module, connected to the DI acquisition module, is used to analyze the operating characteristic parameter information of several reactors and output control signals, including: The data analysis unit, which is connected to the DI acquisition module, is used to analyze the operating characteristic values ​​of the reactors based on the operating characteristic parameter information of each reactor. A risk prediction unit, connected to the data analysis unit, is used to determine the execution frequency of the control algorithm based on the operating characteristic characterization values ​​of each reactor to determine the operating characteristic parameter information of each reactor. A standard evaluation unit, which is connected to the risk prediction unit, is used to determine whether the operation of the IO terminal meets the standard based on the execution frequency of the control algorithm based on the operating characteristic parameter information of several reactors. A redundant power supply is provided to power the PCB board and the internal I / O module. A redundant communication interface is provided for controlling the signals of the internal I / O module. Terminal blocks are used for electrical connections to sensors and actuators used to control target areas within the workshop. An explosion-proof enclosure is installed outside the I / O terminal to protect the I / O terminal from explosion, corrosion, and signal interference. The operational characteristic parameters include: liquid temperature inside the reactor, inlet temperature of the reactor jacket, outlet temperature of the reactor jacket, internal pressure of the reactor, and outlet pressure of the reactor jacket.

2. The industrial field distributed I / O terminal of the explosion-proof enclosure according to claim 1, characterized in that, The data analysis unit determines the operating characteristic value of each reactor by summing the first reactor operating characteristic parameter, the second reactor operating characteristic parameter, the third reactor operating characteristic parameter, the fourth reactor operating characteristic parameter, and the fifth reactor operating characteristic parameter. The operating characteristic parameters of the first, second, third, fourth, and fifth reactors are calculated using the liquid temperature inside each reactor, the inlet temperature of the reactor jacket, the outlet temperature of the reactor jacket, the internal pressure of the reactor, and the outlet pressure of the reactor jacket, respectively.

3. The industrial field distributed I / O terminal of the explosion-proof enclosure according to claim 1, characterized in that, The risk prediction unit is used to determine that each reactor is in an operational risk cycle based on the condition that the operating characteristic characterization value of each reactor is less than or equal to a predetermined operating characteristic characterization value threshold.

4. The industrial field distributed I / O terminal of the explosion-proof enclosure according to claim 1, characterized in that, The risk prediction unit is used to determine the increase in the execution frequency of the control algorithm for the operating characteristic parameters of each reactor based on the ratio of the reactor's operating characteristic characterization value to a predetermined operating characteristic characterization value threshold when each reactor is in an operating risk cycle.

5. The industrial field distributed I / O terminal of the explosion-proof enclosure according to claim 1, characterized in that, The standard evaluation unit determines whether the operation of the IO terminal conforms to the standard based on the control algorithm of the reactor's operating characteristic parameter information, the number of reactors controlled by the algorithm with an execution frequency greater than or equal to a preset frequency threshold; If the number of controlled reactors exceeds a preset threshold, the IO terminal is determined to be operating incorrectly.

6. The industrial field distributed I / O terminal of the explosion-proof enclosure according to claim 1, characterized in that, The explosion-proof enclosure is made of 304 stainless steel with a brushed surface. The explosion-proof marking of the explosion-proof enclosure is Exd IIBT6 Gb.

7. The industrial field distributed I / O terminal of the explosion-proof enclosure according to claim 1, characterized in that, The DI acquisition module and the DO control module are detachable. The acquisition module also includes a detachable AI acquisition module, and the control module also includes a detachable AO control module.

8. The industrial field distributed I / O terminal of the explosion-proof enclosure according to claim 7, characterized in that, The corrosion resistance rating of the explosion-proof enclosure is F2; The explosion-proof enclosure has an IP65 protection rating.

9. The industrial field distributed I / O terminal of the explosion-proof enclosure according to claim 6, characterized in that, It also includes wiring rules for industrial sites based on the distributed I / O terminal, including: Place several of the aforementioned IO terminals in the target area of ​​the industrial site; Several cables are laid out based on the wiring terminals of each IO terminal to connect several sensors that collect information on the operating characteristic parameters of the reactor. Two communication cables are laid to connect the central control room in the industrial site based on the redundant communication interfaces of each IO terminal. The redundant communication interface includes two communication interfaces.

10. A control system for an industrial field distributed I / O terminal for an explosion-proof enclosure according to any one of claims 1-9, characterized in that, include: The DI acquisition module is used to collect operational characteristic parameter information of several reactors in the target area of ​​the industrial site; The DO control module, connected to the DI acquisition module, is used to analyze the operating characteristic parameters of several reactors and output control signals, including: The data analysis unit, which is connected to the DI acquisition module, is used to analyze the operating characteristic values ​​of the reactors based on the operating characteristic parameter information of each reactor. A risk prediction unit, connected to the data analysis unit, is used to determine the execution frequency of the control algorithm based on the operating characteristic characterization values ​​of each reactor to determine the operating characteristic parameter information of each reactor. A standard evaluation unit, which is connected to the risk prediction unit, is used to determine whether the operation of the IO terminal meets the standard based on the execution frequency of the control algorithm based on the operating characteristic parameter information of several reactors. The power control unit, which is connected to the risk prediction unit and the standard evaluation unit, is used to determine the control algorithm execution frequency threshold for adjusting the reactor's operating characteristic parameter information when the IO terminal does not meet the standard, or to determine to start the redundant power supply.

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