Flexible diversified low-voltage power supply device and system for tunneling equipment control system
By designing a flexible and diversified low-voltage power supply device, and using the STM32F103C8T6 embedded chip and the unbalanced bridge method, the problems of confusion and reliability in the power supply system of tunneling equipment were solved. Automatic switching and insulation detection were realized, the system integration and stability were improved, and the cost was reduced.
Patent Information
- Application Number
- CN202511388860.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-26
- Publication Date
- 2025-12-16
AI Technical Summary
Existing power supply systems for tunneling equipment suffer from problems such as disorganization, poor reliability, low stability, low integration, high cost, and inability to achieve automatic power load switching.
A flexible and diversified low-voltage power supply device was designed, which includes a transformer unit, a power supply unit, a transition plate and wiring harness unit, and a power acquisition and protection unit. The device uses an STM32F103C8T6 embedded chip for power acquisition and protection, and uses the unbalanced bridge method to realize insulation status detection and leakage protection. It also integrates a temperature control switch and anti-misinsertion and anti-misplugging functions.
It simplifies the design of the electrical system for tunneling equipment, optimizes the layout structure, reduces material costs, improves production efficiency, realizes automatic switching of power load and insulation detection, and enhances the reliability and stability of the system.
Smart Images
Figure CN121150461A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the field of electrical control system, in particular to a flexible multi-element low-voltage power supply device and system for heading equipment control system. BACKGROUND
[0002] Heading equipment is the core equipment of underground roadway development. With the development of intelligent technology, heading equipment has formed three systems of environment perception, execution control and network construction. Different manufacturers adopt different strategies for power supply of the three systems, and mostly increase the power supply system in a stacking manner, causing chaos in the power supply and distribution system of heading equipment, poor reliability, stability and expandability, increasing the complexity of system design, and increasing the system's formed and unformed costs.
[0003] With the development of heading equipment, its core control system has basically formed an industry consensus, mostly built by PLC to build a control center, sensors such as pressure, temperature and angle to build a perception center, switches, bus modules, etc. to build a network system, and configure corresponding intrinsic safety power supply, switching power supply according to different system requirements. The market mostly selects mature products. The power supply system built is very different, with low integration level and high cost. Its protection is not complete, mostly realized by air switch for short circuit protection, and no power supply commonality is extracted according to the physical characteristics of the power supply object. Design a dedicated power supply system, and if the power supply source fails, it cannot automatically switch the power load of the core system. SUMMARY
[0004] Therefore, the purpose of the present application is to provide a flexible multi-element low-voltage power supply device and system for heading equipment control system to solve the technical problem that the existing system has poor use effect and certain defects.
[0005] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a flexible multi-element low-voltage power supply device for heading equipment control system, comprising a transformer unit, a power supply unit, a transition plate, a wire harness unit and an electric quantity acquisition and protection unit; The transformer unit is used to provide AC220V, AC127V and AC36V multi-level alternating voltage output, and the primary side is provided with a high-voltage quick plug-in terminal, and the secondary side is provided with a low-voltage quick plug-in terminal; The electric quantity acquisition and protection unit is built based on an STM32F103C8T6 embedded chip, comprising an alternating current sampling module, a load adjustment module and a protection module; the alternating current sampling module acquires voltage and current signals of the secondary side of the transformer unit through a voltage transformer and a current sensor, and transmits the signals to the STM32F103C8T6 embedded chip after signal processing; the load adjustment module is used to realize automatic switching of power supply load; the protection module realizes ground insulation state detection and leakage protection of different voltage levels by using an unbalanced bridge method; The power supply unit is used for converting AC 220V into DC 24V, and realizes flexible adjustment of direct current power supply in cooperation with the load adjustment module; The transition plate and wire harness unit are used for realizing the connection between units and external equipment, and have the functions of preventing wrong insertion and insertion error.
[0006] The transformer unit is in the shape of a cuboid, adopts a metal shell and is integrally poured with epoxy resin inside; the magnetic core adopts a non-closed magnetic core structure of non-annular silicon steel sheet, and the high-voltage winding and the low-voltage winding are wound on the same iron core column; a temperature control switch is embedded inside the transformer unit, and the lead-out wire of the temperature control switch is connected to the output terminal; four bending structures are arranged around the transformer unit.
[0007] The load adjustment module converts the collected current signal into active power through Fourier transform and Kalman filter algorithm; the full load is set as 85% of the rated load, when the load capacity reaches or approaches the full load, the power supply source is automatically switched through a high-voltage and large-current relay; the DC 24V level of the power supply source includes 3.5A, 5A, 7.5A, 10A and 12A.
[0008] The protection module adopts a relay module G6S-2F-TRDC5 as a detection line switching device, detects the voltages of different nodes to calculate the total voltages U, U2 and U3 by controlling the on-off state of KEY1, KEY2 and KEY3, and obtains the ground insulation resistances R6 and R7 under different voltage levels by substituting into the voltage relationship formula; the protection module realizes the corresponding leakage protection resistance value according to the requirements of the national standard GB3836 for different voltage levels.
[0009] The transition plate and wire harness unit include a transition plate and an external quick connection structure; the transition plate is connected with the transformer unit through the external quick connection structure with different colors and different terminal numbers, is used for distributing AC 220V, AC 127V, AC 36V and DC 24V voltages, and is provided with a relay assembly on the transition plate to realize flexible power supply switching; 2P-10P sockets are installed on the transition plate to realize insertion error prevention through color, terminal row number and type; the external connection structure includes a program download port, a debugging port and a connection panel, the connection panel is connected with external power supply equipment in a quick plug-in and plug-out mode, and is provided with a blue LED metal indicator lamp for displaying the internal state.
[0010] A flexible multi-element low-voltage power supply system for tunneling equipment, comprising a display unit connected with an electric quantity acquisition and protection unit, used for displaying the operating parameters of the power supply system.
[0011] In summary, the present application has the following beneficial effects: 1. The application proposes a general tunneling equipment flexible multi-element low-voltage power supply device and system, which can simplify the design of tunneling equipment electrical system, optimize the layout structure, improve production efficiency and reduce material cost. 2. The application applies the three unbalanced bridge test methods to the coal mine tunneling equipment to solve the drift problem caused by the traditional voltage comparison method. 3. The application introduces square transformer and non-closed magnetic core structure into the tunneling equipment electrical control system, and integrates temperature control switch in the control transformer, effectively solving the high temperature problem caused by residual magnetism. BRIEF DESCRIPTION OF DRAWINGS
[0012] Figure 1 The application is a tunneling equipment flexible multi-element low-voltage power supply device system structure diagram. Figure 2 The application is a tunneling equipment flexible multi-element low-voltage power supply device external structure diagram. Figure 3 The application is a tunneling equipment flexible multi-element low-voltage power supply device control block diagram. Figure 4 The application is a tunneling equipment flexible multi-element low-voltage power supply device internal structure diagram. Figure 5 The application is an unbalanced bridge method insulation detection circuit diagram a. Figure 6 The application is an unbalanced bridge method insulation detection circuit diagram b. Figure 7 The application is an unbalanced bridge method insulation detection circuit diagram c.
[0013] In the figure: 1, transformer unit; 2, debugging port; 3, program download port; 4, external quick connection port; 5, display unit; 6, power supply unit; 7, transition plate and wire harness unit; 8, electric quantity acquisition and protection unit. DETAILED DESCRIPTION
[0014] The technical solutions in the embodiments of the application will be described clearly and completely below with reference to the drawings in the embodiments of the application. The embodiments described below with reference to the drawings are exemplary and are used to explain the application, and cannot be understood as a limitation of the application.
[0015] The embodiments of the application will be described below according to the overall structure of the application.
[0016] A tunneling equipment flexible multi-element low-voltage power supply device and system includes the following steps: Step 1: Establish an exchange power model of mining equipment under big data, design a small, light, high power density transformer, fast connection of primary and secondary sampling, and establish a general transformer unit that meets different voltage levels and capacity requirements.
[0017] Step 2: Establish an AC sampling and load conversion system based on embedded chip STM32F103C8T6, realize flexible power supply system, realize efficient energy saving and safe system, as shown in Figure 3
[0018] Step 3: Based on the fast plug, build the internal and external structure of the flexible multi-element low-voltage power supply device of the tunneling equipment, realize the anti-misplug and anti-misplug connection system, as shown in Figure 2 and Figure 4
[0019] Further, the establishment of an exchange power model of mining equipment under big data, the design of a small, light, high power density transformer, fast connection of primary and secondary sampling, and the establishment of a general transformer unit that meets different voltage levels and capacity requirements, which contains the following specific steps: a. The appearance of the transformer is a cuboid shape, the high-voltage input port, i.e. the primary side, uses 2P high-voltage quick plug terminals, and the low-voltage output, i.e. the secondary side, uses 8P low-voltage quick plug terminals; b. The whole transformer uses bright light spray metal shell and epoxy resin whole pouring to make the product more integrated, which can be completely applied to the application scene of frequent vibration.
[0020] At the same time, the transformer uses epoxy resin pouring inside, which can greatly reduce the creepage distance and discharge gap between high-voltage and low-voltage windings, and the volume is minimized; c. The bottom carrying structure of the transformer: the transformer is provided with four bending structures around the four corners, which is convenient for carrying before the installation of the transformer; d. The winding inside the transformer is embedded with a temperature control switch and led out to an external separate output terminal, which can prewarn and protect the internal overheating of the transformer; e. The transformer core uses non-ring silicon steel sheet with low loss, and the core adopts non-closed core structure, which can effectively avoid the damage of residual magnetism to the coil, and the core structure is also wound on one core column for high and low voltage, which effectively reduces the leakage magnetic of high and low voltage, realizes good coupling performance of ring core high and low voltage, and avoids the too large instantaneous current of ring core when energized; f. The design parameters of the transformer are: total capacity 1500VA, input AC1140V / 660V / 1.32A / 2.27A, output AC220V / 3.5A / 770W, AC127V / 4.5A / 570W, AC36V / 4.5A / 160W, and the volume is length width height = 175*200*130mm.
[0021] Further, the AC sampling, load conversion, protection system based on the embedded chip STM32F103C8T6 realizes flexible power supply, comprising the following steps: a. AC sampling system: collect the voltage and current parameters of the secondary side of the transformer, HTP225A-G is a voltage transformer, CT203 is a current sensor, realize the collection of AC220V, AC127V, AC36V voltage and current signals, the collected signals enter the RN7302 chip for signal processing and conversion. The converted and isolated signals are operated by the STM32F103C8T6 system; b. Load adjustment system: The load adjustment system is for the DC power supply side, AC220 to DC24 is realized by the sampling power module, the collected current signal is Fourier transformed, and the active power is converted into the active power by the Kalman filter algorithm, the full load is set to 85% of the rated load, the value can be set by itself, when the load capacity approaches or reaches the set value, the power supply source is automatically switched, the sampling high-voltage and high-current relay is used in the switching system, and the power supply source is DC24 / 3.5A, DC24 / 5A, DC24 / 7.5A, DC24 / 10A, DC24 / 12A five levels, which can be automatically switched according to the load conversion; c. Protection system: for the AC power supply system, the unbalanced bridge method is used to realize the ground insulation state of AC220V, AC127V, AC36V side, and the relay module G6S-2F-TRDC5 is used as the detection line switching.
[0022] Further, the protection system comprises the following steps: (1) As shown in Figure 5 , when KEY1, KEY2 and KEY3 are all disconnected, the total voltage U can be calculated by detecting the voltage of R3; (2) As shown in Figure 6 , when KEY1 and KEY3 are closed and KEY2 is disconnected, the upper end is connected to R4, and the lower end voltage Ub (U2) can be calculated by detecting the voltage of R3, and the upper end voltage Ua = U-Ub; Voltage relationship 1: (3) As shown in Figure 7 , when KEY2 and KEY3 are closed and KEY1 is disconnected, the lower end is connected to R5, and the lower end voltage Ub (U3) can be calculated by detecting the voltage of R3, and the upper end voltage Ua = U-Ub Voltage relationship 2: (4) According to the above relationship, the total voltage U, U2 and U3 can be calculated: Given voltage relationship 1 and voltage relationship 2, by substituting U, U2, and U3 into the voltage relationship, the precise resistance values of the insulation resistance to ground R6 and R7 under different voltage levels can be obtained.
[0023] (5) According to the requirements of the national standard GB3836, different leakage protection resistance values are achieved for different voltage levels.
[0024] Furthermore, based on quick-connect plugs, a flexible and diversified low-voltage power supply device internal and external structure is constructed for tunneling equipment to achieve a system that prevents mis-plugging and incorrect connection. This includes the following steps: a. The internal structure of the flexible and diversified low-voltage power supply device for tunneling equipment includes a transformer unit, a transition unit, a switch module unit, and a power acquisition and protection unit. Each unit is separated according to its function and structure. b. The internal structure connection method uses quick-connect devices with different colors and different numbers of terminals. The transformer is used as the terminal block, and the connection is led to the transition plate through quick plug. The transition plate distributes AC220V, AC127V, AC36V, and DC24V voltages. At the same time, the transition plate contains relay components for flexible power supply switching. 2P-10P sockets are installed on the transition plate, and incorrect insertion is prevented by color, number of terminal blocks, and terminal block type. c. The external structure of the flexible and diversified low-voltage power supply device for tunneling equipment includes a program download port, a debugging port, and a connection panel. The connection panel connects to the power supply equipment via a quick-plug method and displays the internal status using blue-wave LED metal indicator lights.
[0025] Although embodiments of the present invention have been shown and described, these specific embodiments are merely explanations of the invention and are not intended to limit it. The specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. After reading this specification, those skilled in the art may make modifications, substitutions, and variations to the embodiments as needed without departing from the principles and spirit of the invention, but such modifications, substitutions, and variations are protected by patent law as long as they are within the scope of the claims of the present invention.
Claims
1. A flexible and diversified low-voltage power supply device for tunneling equipment control systems, characterized in that, It includes a transformer unit (1), a power supply unit (6), a transition plate and wiring harness unit (7), and a power acquisition and protection unit (8). The transformer unit (1) is used to provide AC220V, AC127V and AC36V multi-level AC voltage output. Its primary side is provided with high voltage quick-plug terminals and its secondary side is provided with low voltage quick-plug terminals. The power acquisition and protection unit (8) is built on the STM32F103C8T6 embedded chip and includes an AC sampling module, a load adjustment module and a protection module. The AC sampling module acquires the voltage and current signals of the secondary side of the transformer unit through a voltage transformer and a current sensor, and transmits them to the STM32F103C8T6 embedded chip after signal processing. The load adjustment module is used to realize the automatic switching of power supply load. The protection module uses the unbalanced bridge method to realize the detection of the insulation status to ground and leakage protection of different voltage levels. The power supply unit (6) is used to convert AC220V to DC24V, and works with the load adjustment module to achieve flexible adjustment of DC power supply; The transition plate and wiring harness unit (7) are used to realize the connection between each unit and with external equipment, and have the functions of preventing mis-insertion and preventing incorrect insertion.
2. The flexible and diversified low-voltage power supply device for tunneling equipment control systems according to claim 1, characterized in that: The transformer unit (1) is rectangular in shape, with a metal shell and an interior encapsulated with epoxy resin. Its magnetic core adopts a non-circular silicon steel sheet non-closed magnetic core structure, and the high-voltage winding and low-voltage winding are wound on the same iron core column. A temperature control switch is embedded inside the transformer unit, and the lead wire of the temperature control switch is connected to the output terminal. The transformer unit has four bending structures around its perimeter.
3. The flexible and diversified low-voltage power supply device for tunneling equipment control systems according to claim 1, characterized in that: The load adjustment module converts the collected current signal into active power through Fourier transform and Kalman filtering algorithm; the full load is set to 85% of the rated load, and when the load capacity reaches or approaches the full load, the power supply head is automatically switched through a high-voltage, high-current relay; the DC24V rating of the power supply head includes 3.5A, 5A, 7.5A, 10A, and 12A.
4. The flexible and diversified low-voltage power supply device for tunneling equipment control systems according to claim 1, characterized in that: The protection module uses a relay module G6S-2F-TRDC5 as a detection line switching device. By controlling the on / off state of KEY1, KEY2, and KEY3, it detects the voltage of different nodes to calculate the total voltages U, U2, and U3, and substitutes them into the voltage relationship formula to obtain the ground insulation resistances R6 and R7 under different voltage levels. The protection module implements corresponding leakage protection resistance values for different voltage levels in accordance with the national standard GB3836.
5. A flexible and diversified low-voltage power supply device for tunneling equipment control systems according to claim 1, characterized in that: The transition plate and wiring harness unit (7) includes a transition plate and an external quick-connect structure (4); the transition plate is connected to the transformer unit (1) through external quick-connect structures (4) of different colors and different terminal numbers, for distributing AC220V, AC127V, AC36V, and DC24V voltages, and the transition plate is equipped with a relay assembly to realize flexible power supply switching. The transition plate is equipped with 2P-10P sockets, and the color, terminal block number and type are used to prevent incorrect insertion; the external connection structure includes a program download port (3), a debugging port (2) and a connection panel. The connection panel is connected to the external power supply equipment through quick plug-in method, and is equipped with a blue wave LED metal indicator light to display the internal status.
6. A flexible and diversified low-voltage power supply system for tunneling equipment, characterized in that, The device includes any one of the flexible and diversified low-voltage power supply devices for tunneling equipment as described in any one of claims 1-5, and further includes a display unit (5), which is connected to the power acquisition and protection unit (8) and is used to display the operating parameters of the power supply system.