Uninterruptible power supply (UPS) maintenance bypass system and method for polyester production device

Abstract

The invention relates to the technical field of industrial uninterruptible power supplies, in particular to an uninterruptible power supply (UPS) maintenance bypass system applied to continuous production processes of chemical fibers, chemical engineering and the like and an operation method thereof, and an intelligent detection unit and an intelligent control unit are innovatively introduced into the system on the basis of a traditional wire inlet switch, a wire outlet switch, a maintenance bypass switch and a UPS. The intelligent detection unit is used for accurately detecting the voltage, frequency and phase synchronism of the two ends of the maintenance bypass switch, and the intelligent control unit is used for automatically or guiding an operator to execute safe switching operation based on a detection result and safe interlocking logic. According to the invention, the problems that the traditional UPS maintenance bypass operation depends on artificial experience and has power-off and short-circuit risks are solved, absolutely safe and reliable non-power-off maintenance on the UPS in continuous industrial processes such as polyester production is realized, and the stability and continuity of production are guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of industrial uninterrupted power supply, in particular to an uninterrupted power supply (UPS) maintenance bypass system applied to continuous production processes of chemical fibers and chemical industry and an operation method thereof. BACKGROUND

[0002] In modern chemical fiber production processes, polyester devices are the core production equipment. The DCS and instrument control system of the polyester device has very high requirements for power supply continuity. Instantaneous power failure may cause production interruption, material solidification and equipment damage, resulting in huge economic losses. Therefore, these key control systems are usually powered by industrial UPS.

[0003] At present, the common UPS system is usually equipped with a static bypass and a maintenance bypass. The static bypass is used to automatically switch to the mains when the UPS internal fault occurs, but its switching depends on the normal work of the UPS internal electronic elements. When the UPS host needs to be shut down for maintenance, battery replacement or internal overhaul, the traditional maintenance bypass operation has the following technical pain points: Complex operation and experience-dependent: The operator needs to manually operate multiple switches in strict sequence, and there is a risk of human error in the operation process. Once the sequence is wrong (such as disconnecting the UPS input and output first, and then closing the maintenance bypass), the load will be powered off.

[0004] Lack of state verification: Before closing the maintenance bypass, the operator cannot accurately and intuitively confirm whether the voltage, frequency and phase of the two ends of the maintenance bypass are completely synchronized with the main circuit. Only relying on simple voltage indication cannot ensure that there is no loop current or impact at the moment of closing, which poses a potential threat to the equipment and load.

[0005] No safety interlocking: The traditional mechanical switch or circuit breaker lacks mandatory electrical or mechanical interlocking between them, and there is a risk of misoperation that the UPS input and output switch and the maintenance bypass switch are closed at the same time, forming a short circuit path.

[0006] Low degree of intelligence: The entire switching process lacks recording, monitoring and remote control capabilities, which does not meet the requirements of modern intelligent factories for key power systems to be manageable, controllable and visualized.

[0007] Therefore, there is an urgent need in the art for a solution that can achieve safe, reliable and intelligent uninterrupted power supply (UPS) maintenance switching. SUMMARY

[0008] The present application relates to the technical field of industrial uninterrupted power supply, in particular to an uninterrupted power supply (UPS) maintenance bypass system applied to continuous production processes of chemical fibers and chemical industry and an operation method thereof.

[0009] Another object of the present application is to provide an operation method based on the above system, which is logical and introduces automatic detection and intelligent interlocking to minimize the risk of human error.

[0010] Still another object of the present application is to realize state monitoring, remote control and fault diagnosis of the system by introducing an intelligent control unit, thereby improving the intelligent level of the system.

[0011] Technical scheme: A non-power UPS maintenance bypass system for a polyester production device, comprising: an incoming line switch, an outgoing line switch, a maintenance bypass switch and a UPS host. The input end of the UPS host is connected to the incoming line of commercial power through the incoming line switch, and the output end is connected to the key load through the outgoing line switch. One end of the maintenance bypass switch is connected to the incoming line of commercial power, and the other end is connected to the key load.

[0012] In further embodiments, the system further comprises: An intelligent detection unit connected to both ends of the maintenance bypass switch and configured to detect and compare electrical parameters at both ends of the maintenance bypass switch and output the comparison result; An intelligent control unit in communication connection with the incoming line switch, the outgoing line switch, the maintenance bypass switch and the intelligent detection unit, and configured to control the opening and closing operations of the incoming line switch, the outgoing line switch and the maintenance bypass switch based on the comparison result output by the intelligent detection unit.

[0013] In further embodiments, the electrical parameters include voltage amplitude, frequency and phase; the intelligent detection unit includes a voltage sensor, a frequency detection circuit and a phase comparator, and is configured to output a synchronization confirmation signal to the intelligent control unit when the voltage vector difference at both ends of the maintenance bypass switch is less than a preset safety threshold.

[0014] In further embodiments, the system further comprises a safety interlocking module configured to enforce an interlocking logic that the incoming line switch, the outgoing line switch and the maintenance bypass switch cannot be in a closed state at the same time.

[0015] In further embodiments, the safety interlocking module is realized through software logic of the intelligent control unit and / or through hardware wiring mode of connecting auxiliary contacts of each switch into the control circuit of other switches.

[0016] In further embodiments, the system further comprises a human-computer interaction interface connected with the intelligent control unit for real-time display of system operation mode, switch state, comparison result of the intelligent detection unit and reception of operation instructions.

[0017] In further embodiments, the intelligent control unit is a programmable logic controller (PLC) or an embedded microcontroller.

[0018] A method for maintenance operation of an uninterruptible power supply (UPS) without power interruption, comprising a switching step from a normal operation mode to a maintenance bypass mode, the switching step comprising: detecting, by the intelligent detection unit, a synchronization state of electrical parameters across the maintenance bypass switch; controlling, by the intelligent control unit, to close the maintenance bypass switch upon confirming the synchronization of the electrical parameters; controlling, by the intelligent control unit, to sequentially open the outgoing switch and the incoming switch upon confirming the closing of the maintenance bypass switch.

[0019] In further embodiments, in the switching step, if the intelligent detection unit detects that the electrical parameters are not synchronized, the intelligent control unit locks the system and issues an alarm, and prohibits closing the maintenance bypass switch.

[0020] In further embodiments, the method further comprises a switching back step from the maintenance bypass mode to the normal operation mode, the switching back step comprising: detecting, by the intelligent detection unit, a synchronization state of electrical parameters between the output of the UPS host and the load powered by the maintenance bypass; controlling, by the intelligent control unit, to sequentially close the incoming switch and the outgoing switch upon confirming the synchronization; controlling, by the intelligent control unit, to open the maintenance bypass switch upon confirming the closing of the incoming switch and the outgoing switch.

[0021] In further embodiments, the intelligent control unit records and stores operation instructions, switch state changes, and detection unit data during all mode switching processes.

[0022] Compared with the prior art, the present application has the following advantages: 1. Absolute safety and reliability: By accurately comparing voltage vectors through the intelligent detection unit, it is ensured that the maintenance bypass is only allowed to be closed under the condition of absolute synchronization, completely avoiding current surges during the switching process, and protecting the equipment and load. The safety interlocking module completely eliminates short circuit accidents caused by human error.

[0023] 2. Ease and intelligence of operation: Complex, experience-dependent manual operations are converted into one-key or step-by-step confirmation semi-automatic / automatic operation processes guided by the intelligent control unit, greatly reducing the operation threshold and error rate.

[0024] 3. State visualization and traceability: The human-machine interface displays all key information in real time, making the operation process transparent. The intelligent control unit can record all operation logs and alarm information, facilitating post-analysis and fault diagnosis.

[0025] 4. Remote operation and maintenance capability: The intelligent control unit can integrate a network communication module, supporting remote monitoring and receiving operation instructions, and adapting to the needs of modern chemical plants without on-site personnel or centralized monitoring.

[0026] 5. Wide applicability: This system is not only suitable for polyester production devices in the chemical fiber industry, but also for any industrial scenario that requires high reliability and continuous power supply, such as data centers, semiconductor production lines, and precision chemical industries. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 is the overall structure diagram of the system of the present application.

[0028] Figure 2 is the internal structure principle diagram of the intelligent detection unit of the present application.

[0029] Figure 3 is the normal operation mode schematic diagram of the system of the present application.

[0030] Figure 4 is the switching preparation stage (synchronous detection) schematic diagram of the present application.

[0031] Figure 5 is the maintenance bypass closure instant schematic diagram of the present application.

[0032] Figure 6 is the UPS isolation maintenance state schematic diagram of the present application.

[0033] Figure 7 is the safety interlocking logic principle diagram of the present application.

[0034] Figure legend: power line 1, critical load 2, UPS host 3, incoming line switch 4, outgoing line switch 5, maintenance bypass switch 6, intelligent detection unit 7, intelligent control unit 8, human-machine interface 9, voltage sensor 701, signal conditioning circuit 704 / 703, microprocessor 705. DETAILED DESCRIPTION

[0035] The technical solutions of the present application will be described below in conjunction with the drawings. Obviously, the described embodiments are part of the embodiments of the present application, not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor are within the scope of protection of the present application.

[0036] A non-stop UPS maintenance bypass system for a polyester production device, as shown inFigures 1 to 2 As shown, the system includes: an incoming mains power line 1, a critical load 2, a UPS main unit 3, an incoming line switch 4, an outgoing line switch 5, and a maintenance bypass switch 6. The input terminal of the UPS main unit is connected to the incoming mains power line via the incoming line switch, and the output terminal is connected to the critical load via the outgoing line switch. One end of the maintenance bypass switch is connected to the incoming mains power line, and the other end is connected to the critical load.

[0037] The core improvement of this invention is that the system further includes: an intelligent detection unit 7 and an intelligent control unit 8.

[0038] Intelligent detection unit: Connected to both ends of the maintenance bypass switch, it is used to detect and compare the electrical parameters of the maintenance bypass input terminal (connected to the mains side) and output terminal (connected to the load side) in real time. The electrical parameters include at least voltage amplitude, frequency, and phase. This unit integrates a high-precision voltage sensor, frequency detection circuit, and phase comparator, and can calculate the vector difference of the voltages at both ends, not just a simple potential difference.

[0039] Intelligent control unit: This unit is communicatively connected to the incoming line switch, outgoing line switch, maintenance bypass switch, and intelligent detection unit. Preferably, this unit is a PLC or a dedicated microcontroller with built-in safety switching logic. This unit receives the comparison results from the intelligent detection unit and outputs control commands based on these results to control the opening and closing operations of each switch.

[0040] Safety interlock module: Exists as part of the intelligent control unit or as independent hardware, achieving strict electrical interlocking through hard wiring or software logic. Its interlocking logic is as follows: the maintenance bypass switch, the incoming switch, and the outgoing switch cannot be simultaneously closed, thus fundamentally eliminating the risk of power short circuits.

[0041] Status indicators and human-machine interface: The system is also equipped with status indicator lights and / or touch screens to display the current operating mode of the system (mains-UPS mode, maintenance bypass mode), the status of each switch, and the detection results of the intelligent detection unit (such as "synchronization is good, switchable" or "desynchronization, operation prohibited") in real time, providing clear guidance for operators.

[0042] For the specific circuit configuration of the intelligent detection unit 7, please refer to [link / reference]. Figure 2It includes two high-precision voltage sensors 701, which respectively collect the voltage signals across the maintenance bypass switch. After passing through conditioning circuits 703 and 704, the signals are sent to a high-performance microprocessor 705. The microprocessor 705 runs an algorithm to calculate the amplitude difference ΔU, frequency difference Δf, and phase difference Δθ between the two voltages. The microprocessor 705 will only output a "synchronization confirmation" signal to the intelligent control unit 8 if and only if ΔU, Δf, and Δθ are all less than preset safety thresholds (e.g., ΔU < 2V, Δf < 0.1Hz, Δθ < 2°).

[0043] The intelligent control unit 8 uses an industrial-grade PLC. Its I / O points are connected to the closing / opening coils and auxiliary contacts of each switch, and it is connected to the intelligent detection unit 7 and the touch screen 9 via a communication interface (such as RS485). The PLC internally stores... Figure 6 The security switching logic program is shown.

[0044] The safety interlock module is implemented through PLC hardware wiring: the normally closed auxiliary contact of the maintenance bypass switch 6 is connected in series into the closing circuit of the incoming switch 4 and the outgoing switch 5; at the same time, the normally closed auxiliary contacts of the incoming switch 4 and the outgoing switch 5 are connected in series into the closing circuit of the maintenance bypass switch 6. This constitutes a triple hardware interlock, ensuring that the three switches cannot be energized and closed simultaneously.

[0045] The system works as follows: Normal operating mode ( Figure 3 ( ): Incoming switch 4 and outgoing switch 5 are closed, and maintenance bypass switch 6 is open. The mains power is regulated and filtered by the UPS host 3 before supplying power to load 2. The intelligent detection unit 7 continuously monitors but does not perform any control function.

[0046] Switch to maintenance bypass mode ( Figure 4 & Figure 6 ): a. The operator selects "Switch to maintenance bypass" mode on touchscreen 9.

[0047] b. The intelligent control unit 8 first obtains the synchronization status of both ends of the maintenance bypass switch through the intelligent detection unit 7.

[0048] c. If the states are out of sync, the touchscreen 9 will display a warning and prohibit subsequent operations.

[0049] d. If the status is synchronized, the touchscreen 9 will display "Conditions met, prepare to switch". After the operator confirms, the intelligent control unit 8 will first issue a command to close the maintenance bypass switch 6.

[0050] e. After confirming that the maintenance bypass switch 6 is reliably closed, the intelligent control unit 8 issues a command to sequentially disconnect the outgoing switch 5 and the incoming switch 4. At this point, the UPS host 3 is safely and completely isolated from the main circuit, and the load 2 is powered by the maintenance bypass.

[0051] Maintenance bypass mode ( Figure 5 ): With the maintenance bypass switch 6 closed and the incoming switch 4 and outgoing switch 5 open, the UPS main unit 3 can be safely powered off for maintenance.

[0052] Restore to normal operating mode: After maintenance is completed, the above process is executed in reverse, and the intelligent control unit 8 ensures the synchronization and safety of the operation.

[0053] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A non-powered UPS maintenance bypass system for polyester production equipment, comprising: The system comprises an incoming line switch (4) connected between the mains power supply line (1) and the input terminal of the UPS host (3), an outgoing line switch (5) connected between the output terminal of the UPS host (3) and the critical load (2), and a maintenance bypass switch (6) connected in parallel across the UPS host (3), characterized in that the system further comprises: The intelligent detection unit (7) is connected to both ends of the maintenance bypass switch (6) and is configured to detect and compare the electrical parameters at both ends of the maintenance bypass switch (6) and output the comparison result; The intelligent control unit (8) is communicatively connected to the incoming switch (4), the outgoing switch (5), the maintenance bypass switch (6) and the intelligent detection unit (7), and is configured to control the opening and closing operations of the incoming switch (4), the outgoing switch (5) and the maintenance bypass switch (6) based on the comparison results output by the intelligent detection unit (7).

2. The uninterruptible UPS maintenance bypass system for polyester production equipment according to claim 1, characterized in that, The electrical parameters include voltage amplitude, frequency and phase; the intelligent detection unit (7) includes a voltage sensor, a frequency detection circuit and a phase comparator, and is configured to output a synchronous confirmation signal to the intelligent control unit (8) when the voltage vector difference across the maintenance bypass switch (6) is less than a preset safety threshold.

3. The uninterruptible UPS maintenance bypass system for polyester production equipment according to claim 2, characterized in that, The system also includes a safety interlock module, which is configured to enforce an interlock logic that prevents the incoming switch (4), outgoing switch (5) and maintenance bypass switch (6) from being closed at the same time.

4. A non-stop UPS maintenance bypass system for polyester production equipment according to claim 3, characterized in that, The safety interlock module is implemented through the software logic of the intelligent control unit (8) and / or through hardware wiring by connecting the auxiliary contacts of each switch in series into the control circuit of other switches.

5. A non-stop UPS maintenance bypass system for polyester production equipment according to claim 1, characterized in that, The system also includes a human-machine interface (9), which is connected to the intelligent control unit (8) and is used to display the system operation mode, the status of each switch, the comparison results of the intelligent detection unit (7) in real time, and to receive operation instructions.

6. The uninterruptible UPS maintenance bypass system for polyester production equipment according to claim 1, characterized in that, The intelligent control unit (8) is a programmable logic controller (PLC) or an embedded microcontroller.

7. A method for maintaining and repairing an uninterrupted power supply UPS based on the system described in any one of claims 1-6, characterized in that, This includes the step of switching from normal operation mode to maintenance bypass mode, the switching step including: The intelligent detection unit (7) detects the synchronization status of electrical parameters at both ends of the maintenance bypass switch (6); After confirming the synchronization of the electrical parameters, the intelligent control unit (8) controls the closure of the maintenance bypass switch (6). After confirming that the maintenance bypass switch (6) is closed, the intelligent control unit (8) controls the sequential disconnection of the outgoing switch (5) and the incoming switch (4).

8. A method for uninterrupted UPS maintenance of a polyester production unit according to claim 7, characterized in that, During the switching process, if the intelligent detection unit (7) detects that the electrical parameters are out of sync, the intelligent control unit (8) locks the system and issues an alarm, prohibiting the closing of the maintenance bypass switch (6).

9. A non-stop UPS maintenance bypass system for polyester production equipment according to claim 7, characterized in that, The method further includes a step of switching back from maintenance bypass mode to normal operation mode, the switching back step including: The intelligent detection unit (7) detects the synchronization status of electrical parameters between the output terminal of the UPS host (3) and the load terminal of the maintenance bypass power supply. After synchronization is confirmed, the intelligent control unit (8) controls the sequential closing of the incoming line switch (4) and the outgoing line switch (5). After confirming that the incoming switch (4) and the outgoing switch (5) are closed, the intelligent control unit (8) controls the disconnection of the maintenance bypass switch (6).

10. A non-stop UPS maintenance bypass system for polyester production equipment according to claim 7, characterized in that, The intelligent control unit (8) records and stores all operation instructions, switch status changes and detection unit data during the mode switching process.

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