Industrial electric equipment power failure fault reporting device and system

Abstract

The invention belongs to the technical field of electric power automation, and particularly relates to an industrial electric equipment power failure fault reporting device and system. The device comprises an internal power supply module, a voltage monitoring module, a controller module, a 485 communication module, a LoRa communication module and a standby power supply module. According to the invention, two analog quantities of an alternating voltage and a direct-current power supply voltage of the device are simultaneously converted into digital switching values, logic processing is carried out, fault discrimination is carried out, and the accuracy of fault information is improved; and meanwhile, after the fault equipment is found, the fault equipment is isolated in time, so that the overall operation efficiency of the system is improved, and the problem of conflict of reported messages when multiple pieces of equipment fail at the same time is effectively solved.

Description

Technical Field

[0001] This invention belongs to the field of power automation technology, specifically, it relates to a power outage fault reporting device and system for industrial electrical equipment. Background Technology

[0002] In industrial production environments, the stable operation of electrical equipment is crucial for ensuring production efficiency and product quality. Sudden power outages can lead to production interruptions, data loss, and even equipment damage, causing significant economic losses to enterprises. Therefore, timely and reliable monitoring and reporting of power outage faults is of great importance. Common power outage reporting devices are typically divided into local alarm devices and remote alarm devices.

[0003] The local alarm device mainly consists of a power supply module, a power failure monitoring module, a backup power supply module, and an output alarm module. The power supply module is responsible for drawing power from the industrial AC voltage of 220V / 380V to power the alarm device; the power failure monitoring module is responsible for monitoring the online or offline status of the AC voltage of 220V / 380V; the backup power supply module is responsible for providing short-term power to the alarm device after the power supply module loses power; and the output alarm module issues an alarm when the industrial power supply is interrupted.

[0004] The remote alarm device mainly consists of a power supply module, a power failure monitoring module, a backup power supply module, and a wireless transmission module. The power supply module, power failure monitoring module, and backup power supply module of the remote alarm device have the same functions as those of a local alarm device. The wireless transmission module is responsible for transmitting the collected factory power consumption information to the upstream network or users; common wireless transmission methods include 4G and LoRa communication. In the event of a power failure, the device can wirelessly transmit alarm information to a cloud platform or the user's mobile phone.

[0005] However, local alarm devices can only issue alarm information within a limited range and cannot transmit alarm information remotely. 4G communication remote alarm devices require "one device and one SIM card" and only support basic power supply status monitoring, lacking the ability to collect key parameters such as voltage / current. LoRa communication passive query mode is prone to triggering repeated commands due to communication failures. In multi-device scenarios, single-point failures will drag down the overall data real-time performance and result in low transmission efficiency.

[0006] Meanwhile, current power outage monitoring in remote alarm devices only monitors industrial AC 220V / 380V power, neglecting to monitor faults in the device's own power supply module. When the industrial power supply is normal, but the device's own power supply module malfunctions, the device may falsely report a power outage, indicating a need to improve its reliability and accuracy.

[0007] No effective solution to the above problems has yet been found. Summary of the Invention

[0008] The technical problem to be solved by this invention is to improve the accuracy and reliability of fault diagnosis in alarm devices. It provides an industrial electrical equipment power failure fault reporting device and system, which simultaneously converts two analog quantities, AC voltage and DC power supply voltage of the device, into digital switch quantities, performs logic processing, and performs fault diagnosis to improve the accuracy of fault information. At the same time, after the faulty equipment is detected, the faulty equipment is isolated in a timely manner, improving the overall operating efficiency of the system and effectively solving the problem of conflicting reporting messages when multiple devices fail at the same time.

[0009] To solve the above technical problems, the technical solution adopted by the present invention is as follows: An industrial electrical equipment power outage fault reporting device, comprising: The internal power supply module converts AC 220V to DC 24V, and the 24V voltage is converted to 3.3V by DC-DC converter to power the STM32F030 module; The voltage monitoring module includes an AC voltage monitoring unit and a DC voltage monitoring unit; The controller module, designed based on the STM32F030 platform, is responsible for the device's data processing and logic operations. The 485 communication module connects to external devices with 485 interface functionality. Through the Modbus protocol, it completes detailed data collection of the power supply voltage, current, frequency, active power, reactive power, apparent power, temperature and humidity of industrial equipment. The collected data is then processed by the controller module. The LoRa communication module is connected to the controller module. During normal operation, it works in transparent transmission mode and waits to receive query commands from the upper layer. When a power failure is detected, it switches to fixed-point transmission mode and actively sends fault information to the LoRa gateway. The LoRa communication module is connected to an external radio frequency antenna. The backup power module uses a supercapacitor or a small lithium battery. When a power failure occurs, the device will switch to backup power supply mode to ensure that fault information can be reliably reported. The backup power module here provides a voltage level of 3.3V and directly supplies power to the controller module.

[0010] The following are further optimizations of the above technical solution by the present invention: The AC voltage monitoring unit is used to convert the external 220V / 380V AC voltage into a digital switch quantity 1, which is high level when there is voltage and low level when there is no voltage. The DC voltage monitoring unit is used to monitor the DC power supply voltage of the device and convert it into a digital switch signal 2. It is high level when there is voltage and low level when there is no voltage.

[0011] Further optimization: The DC voltage monitoring unit requires no external wiring. The internal monitoring circuit is connected to the DC power supply voltage terminal of the device through PCB board traces. The DC voltage monitored here is 24V from the internal power supply module.

[0012] The present invention also provides an industrial electrical equipment power outage fault reporting system. Based on the above-mentioned industrial electrical equipment power outage fault reporting device, the system includes a LoRa gateway and a monitoring cloud platform. The LoRa gateway receives status information and fault information sent by the power outage fault reporting device and uploads the data to the monitoring cloud platform through the Modbus protocol.

[0013] Further optimization: Power outage fault reporting device: Distributed at various industrial electrical equipment locations, it can be regarded as a LoRa node, used to monitor the power supply status of the equipment in real time, collect detailed power consumption data and sensor data, and report fault information.

[0014] Further optimization: LoRa gateway: Receives status and fault information from each power outage reporting device and uploads the data to the monitoring cloud platform via the Modbus protocol.

[0015] Further optimization: The LoRa gateway mainly consists of two LoRa channels and one Ethernet channel. LoRa channel 1 is responsible for all data transmission and reception functions during normal operation, while LoRa channel 2 is used to receive message information transmitted by the LoRa node when the underlying device fails due to power failure.

[0016] Further optimization: Monitoring cloud platform: Receives and processes device status and fault information from LoRa gateways to enable remote monitoring and management of industrial electrical equipment; visualizes the operating status and parameters of industrial electrical equipment; sets multiple associated users; and sends detailed alarm fault information to associated users when fault information is received.

[0017] The present invention adopts the above technical solution and has an ingenious concept. By simultaneously converting two analog quantities, AC voltage and DC power supply voltage of the device, into digital switching quantities, performing logic processing, and identifying faults, the accuracy of fault information is improved. At the same time, after a faulty device is detected, the faulty device is isolated in a timely manner, improving the overall operating efficiency of the system and effectively solving the problem of conflicting reporting messages when multiple devices fail simultaneously. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the power failure reporting device in an embodiment of the present invention; Figure 2 This is a structural diagram of the industrial electrical equipment power outage fault reporting system in an embodiment of the present invention; Figure 3 This is a flowchart of the fault determination process in an embodiment of the present invention; Figure 4 This is a flowchart of the transparent transmission mode in an embodiment of the present invention; Figure 5 This is a flowchart of the fixed-point transmission mode in an embodiment of the present invention; Figure 6 This is a flowchart illustrating the overall system operation in an embodiment of the present invention. Figure 7 This is a flowchart for monitoring power supply status in an embodiment of the present invention. Detailed Implementation

[0019] The present invention will be further described below. Those skilled in the art should understand through the following embodiments that these embodiments are not intended to limit the technical solution of the present invention, but merely to fully illustrate how to implement it.

[0020] Example 1, as Figure 1 As shown, an industrial electrical equipment power failure reporting device includes an internal power supply module, a voltage monitoring module, a controller module, a 485 communication module, a LoRa communication module, and a backup power supply module.

[0021] The internal power supply module converts AC 220V to DC 24V, and the 24V voltage is converted to 3.3V via DC-DC converter to power the STM32F030 module.

[0022] The voltage monitoring module includes an AC voltage monitoring unit and a DC voltage monitoring unit; The AC voltage monitoring unit can convert the external 220V / 380V AC voltage into a digital switch quantity 1, which is high when there is voltage and low when there is no voltage. The DC voltage monitoring unit is used to monitor the DC power supply voltage of the device and convert it into a digital switch signal 2. It is high level when there is voltage and low level when there is no voltage.

[0023] The DC voltage monitoring unit requires no external wiring. The internal monitoring circuit is connected to the DC power supply voltage terminal of the device through PCB board traces. The DC voltage being monitored here is 24V from the internal power supply module.

[0024] In this embodiment, an AC voltage monitoring unit and a DC voltage monitoring unit are used to detect the AC voltage and DC power supply voltage of the device itself, and to convert the two analog quantities of DC voltage and AC voltage into a two-digit switch combination. The fault type is determined by the state of the two-digit switch combination in the program, thereby improving accuracy.

[0025] The controller module, designed based on the STM32F030 platform, is responsible for the device's data processing and logic operations, and is the core for communication between the lower-level devices and the upper-level gateway.

[0026] The 485 communication module connects to external devices with 485 interface functionality, such as electricity meters and temperature and humidity sensors. Through the Modbus protocol, it can collect detailed data such as power supply voltage, current, frequency, active power, reactive power, apparent power, temperature and humidity of industrial equipment, and then send the collected data to the controller module for processing.

[0027] The LoRa communication module is connected to the controller module. During normal operation, it works in transparent mode, waiting to receive query commands from the upper layer. When a power failure is detected, it switches to fixed-point transmission mode and actively sends fault information to the LoRa gateway. The LoRa communication module is connected to an external radio frequency antenna.

[0028] The backup power module uses a supercapacitor or a small lithium battery. When a power failure occurs, the device will switch to backup power supply mode to ensure that fault information can be reliably reported. The backup power module here provides a voltage level of 3.3V and directly supplies power to the controller module.

[0029] like Figure 2 As shown, the industrial electrical equipment power outage fault reporting system, which includes the above devices, also includes a LoRa gateway and a monitoring cloud platform. The LoRa gateway receives status information and fault information sent by the power outage fault reporting device and uploads the data to the monitoring cloud platform via the Modbus protocol.

[0030] Power outage fault reporting device: Distributed at various industrial electrical equipment locations, it can be considered as a LoRa node, used to monitor the power supply status of the equipment in real time, collect detailed power consumption data and sensor data, and report fault information; such as Figure 2 As shown, the power outage fault reporting device, namely LoRa node 1, is connected to the monitoring AC 220V / 380V voltage network, which is the same as the power supply voltage of the underlying devices 1 and 2; LoRa node 2 is connected to the monitoring AC 220V / 380V voltage network, which is the same as the power supply voltage of the underlying devices 3 and 4.

[0031] LoRa Gateway: Receives status and fault information from various power outage reporting devices and uploads the data to the monitoring cloud platform via the Modbus protocol.

[0032] The LoRa gateway mainly consists of two LoRa channels and one Ethernet channel. LoRa channel 1 is responsible for all data transmission and reception functions during normal operation, while LoRa channel 2 is used to receive message information transmitted by the LoRa node when the underlying device fails due to power failure.

[0033] Monitoring cloud platform: Receives and processes device status and fault information from LoRa gateways, enabling remote monitoring and management of industrial electrical equipment. It visualizes the operating status and parameters of industrial electrical equipment, allows for the setting of multiple associated parties, and sends detailed alarm and fault information to these parties upon receiving fault information, facilitating appropriate solutions.

[0034] In this embodiment, the LoRa gateway is designed with two channels. The first channel operates in transparent transmission mode and is used for message transmission and reception during normal operation. The second channel is fixed in fixed-point transmission mode, ready to receive message information sent by the lower-level LoRa node after a device failure and subsequent mode change. In existing technologies, a single LoRa gateway and the lower-level LoRa node can only operate in transparent transmission mode or fixed-point transmission mode. For example, if the gateway is in transparent transmission mode, the LoRa node must also be in transparent transmission mode; if the gateway is in fixed-point transmission mode, the LoRa node must also be in fixed-point transmission mode to communicate. In this scheme, when the host computer polls the devices under the LoRa node, it can only wait when a device fails, which affects transmission efficiency.

[0035] The specific working principle of the power outage fault reporting system includes fault determination methods, LoRa communication logic, and active isolation of faulty devices.

[0036] like Figure 3 As shown, the fault determination method is as follows: The controller module combines the states of switch quantity 1 converted by the AC voltage monitoring unit and switch quantity 2 converted by the DC voltage monitoring unit, where switch quantity 1 is the high bit and switch quantity 2 is the low bit. When the combination is "11", it is in normal operation, and the LoRa gateway maintains transparent transmission mode, communicating bidirectionally through channel 1. When the combination is "10", it is determined to be a power supply failure of the device itself. The LoRa gateway switches to fixed-point transmission mode and sends a fault frame to the cloud platform through channel 2, indicating a power supply failure. The cloud platform alarms and triggers local maintenance. When the combination is "00 or 01", it is determined to be an AC power outage failure. The LoRa gateway switches to fixed-point transmission mode and sends a fault frame to the cloud platform through channel 2, indicating an AC power outage failure. The cloud platform isolates the device and notifies emergency repair. This dual determination mechanism can effectively avoid false alarms caused by a single monitoring point fault and improve the accuracy of fault diagnosis.

[0037] In this embodiment, switch quantity 1 is the high bit and switch quantity 2 is the low bit. This is relative to the two-bit binary combination and refers to the high and low addresses, not the high and low voltage levels. For example, in the combination "10", 1 is the high address bit and 0 is the low address bit.

[0038] LoRa communication mode switching mechanism: Before the system runs, each monitored object is assigned an address, and the addresses of each device cannot be duplicated. The main monitoring objects that need to be connected in this system are the power supply status of electricity meters and electrical equipment. The power supply status of electrical equipment is the switch quantity, and the switch quantity address is configured by the host computer.

[0039] LoRa communication modes include transparent transmission mode and fixed-point transmission mode. When the transparent transmission mode is switched to the fixed-point transmission mode, the device experiences a power failure.

[0040] like Figure 4 As shown, transparent transmission mode: Initially, during normal operation, the cloud platform sends device status information and data collection query Mosbus TCP packets to the LoRa gateway according to preset parameters (such as message sending interval and message reception timeout). Upon receiving the packets, the LoRa gateway converts them into Mosbus RTU format packets and forwards them to the lower-layer LoRa node devices via LoRa channel 1. The LoRa node devices then forward the Mosbus RTU packets to the monitored object via RS485. The monitored object transmits data back to the LoRa gateway via LoRa channel 1, and the LoRa gateway converts the received Mosbus RTU packets into Mosbus TCP packets and sends them to the cloud platform. The data stream on LoRa channel 1 is bidirectional between the upper and lower layers. In transparent transmission mode, if a device fails to return packets or sends abnormal packets, it will cause the cloud platform to receive a timeout. If there are ≥3 timeouts, it is marked as a communication error; if there are <3 timeouts, the timeout information is fed back to the cloud platform. In this case, we do not consider the device to be in a power-off state, because device communication errors or external interference with the wireless transmission signal can also cause reception timeouts. Our sole criterion for determining a power outage fault in a device is the switching of the communication mode of the LoRa node device.

[0041] like Figure 5 As shown, the fixed-point transmission mode: A fixed address and channel are pre-configured for LoRa channel 2 of the LoRa gateway, and it remains in receive mode. In this mode, when a power failure is detected (i.e., the state combination of switch quantity 1 and switch quantity 2 is "10" or "00"), the LoRa node device immediately switches from transparent transmission mode to fixed-point transmission mode and actively sends fault information to LoRa channel 2 of the LoRa gateway. Fixed-point transmission mode employs a carrier sense multiple access with collision avoidance (CSMA / CA) mechanism, listening to the channel before transmission to ensure it is idle before sending data. The data stream of LoRa channel 2 is unidirectional and can only be transmitted from lower-layer devices to the upper-layer cloud platform.

[0042] like Figure 6 As shown, active isolation of faulty equipment: At the LoRa gateway layer, LoRa channel 1 and channel 2 are two tasks assigned by the embedded operating system. Channel 2 is set to have a higher priority than channel 1. When a power failure occurs, channel 2 prioritizes uploading fault information with a power failure flag. After receiving the fault information, the cloud platform parses the address of the faulty device and stops LoRa channel 1 from sending messages to the device at that address, thus completing the active isolation of the faulty device.

[0043] In this embodiment, the working principle of the power failure reporting system is enhanced with an active isolation scheme for faulty devices. When a device fails, the query for messages from that faulty device is stopped immediately. Furthermore, in the LoRa communication logic, existing solutions only offer transparent transmission mode or fixed-point transmission mode. This solution uses the switching between the two modes. The switching condition is that when a fault occurs, the system switches from transparent transmission mode to fixed-point transmission mode.

[0044] The above description provides examples of the preferred embodiments of the present invention. Parts not detailed herein are common knowledge to those skilled in the art. The scope of protection of the present invention is determined by the claims. Any equivalent modifications based on the technical teachings of the present invention are also within the scope of protection of the present invention.

Claims

1. A power outage fault reporting device for industrial electrical equipment, characterized in that: Comprise: Internal power module, AC 220V to DC voltage 24V, 24V voltage through DC-DC conversion to 3.3V for STM32F030 module power supply; Voltage monitoring module, including AC voltage monitoring unit and DC voltage monitoring unit; Controller module, based on STM32F030 platform design, responsible for data processing and logical operation of the device; 485 communication module, 485 communication module and external with 485 interface function device connection, through Modbus protocol, complete the power supply voltage value, current value, frequency, active power, reactive power, apparent power, temperature and humidity data detailed collection, collection for controller module processing; LoRa communication module, connected with the controller module, working in transparent mode in normal operation, waiting to receive the query instruction from the upper layer; When monitoring power failure, switch to fixed-point transmission mode, actively send fault information to LoRa gateway, LoRa communication module external RF antenna; Backup power module, using super capacitor or small lithium battery, when the device in power failure, will switch to backup power supply mode, to ensure that the fault information can be reported reliably; The backup power module here provides a voltage level of 3.3V, directly power supply to the controller module.

2. The power failure reporting device for industrial electrical equipment according to claim 1, characterized in that: The AC voltage monitoring unit is used to convert the external wiring 220V / 380V AC voltage into digital switching value 1, which is high level when there is voltage and low level when there is no voltage. The DC voltage monitoring unit is used to monitor the DC power supply voltage of the device and convert it into digital switching value 2, which is high level when there is voltage and low level when there is no voltage.

3. The power failure reporting device for industrial electric equipment according to claim 1, characterized in that: The DC voltage monitoring unit does not need external wiring, the internal monitoring circuit is connected to the DC power supply voltage end of the device through PCB board wiring, and the monitored DC voltage here is 24V of the internal power module.

4. An industrial power equipment power failure reporting system based on the industrial power equipment power failure reporting device of any one of claims 1-3, characterized in that: The system includes LoRa gateway and monitoring cloud platform, LoRa gateway receives the state information and fault information sent by the power failure reporting device, and uploads the data to the monitoring cloud platform through Modbus protocol.

5. The power failure reporting system for industrial electrical equipment according to claim 4, characterized in that: Power failure reporting device: distributed in each industrial power device, can be regarded as a LoRa node, used for real-time monitoring of device power supply state and collecting detailed power consumption data and sensor data, and reporting fault information.

6. The power failure reporting system for industrial electrical equipment according to claim 4, characterized in that: LoRa gateway: receives the state information and fault information sent by each power failure reporting device, and uploads the data to the monitoring cloud platform through Modbus protocol.

7. The power failure reporting system for industrial electrical equipment according to claim 4, characterized in that: LoRa gateway mainly consists of two LoRa channels and one Ethernet, LoRa channel 1 undertakes all data transmission and reception functions in normal operation, and LoRa channel 2 is used to receive the message information transmitted by LoRa node in power failure of bottom device.

8. The power failure reporting system for industrial electrical equipment according to claim 4, characterized in that: Monitoring cloud platform: receives and processes the device state and fault information from LoRa gateway, realizes remote monitoring and management of industrial power equipment; Visualize the running state and running parameters of industrial power equipment, set multiple associated persons, when receiving fault information, the platform will send detailed alarm fault information to the associated persons.

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