Spatial integrated control loop of electric control cabinet

Abstract

The invention relates to the technical field of electric control loop optimization, in particular to an electric control cabinet space integrated control loop. The execution control and driving module receives the switching instruction, and drives an electric actuator and a motor to open and close a valve through a contactor; the state detection and feedback module is used for converting the working condition of the actuator into a switching value signal and an analog quantity signal and outputting the switching value signal and the analog quantity signal into the control authority and remote interface module; the control authority and remote interface module realizes switching of local and remote control authorities and signal interaction, and supports communication connection with an upper computer or a distributed control system. The functions of switch control, limiting feedback, mode selection, permission switching and the like are integrated in the control panel and the control panel, the number of physical devices and the internal wiring complexity are greatly reduced, the system can achieve remote maintenance / pulse control mode switching according to field requirements, automatic control and manual debugging requirements are considered, and the system flexibility is improved.

Description

Technical Field

[0001] This invention relates to the field of electrical control circuit optimization technology, and in particular to a spatially integrated control circuit for electrical control cabinets. Background Technology

[0002] In existing power plants and large industrial sites, electric actuators are widely used in critical process control scenarios such as valve opening and closing and damper adjustment. In order to achieve remote control and on-site linkage, a dedicated power control cabinet is usually equipped on the actuator to control the forward and reverse rotation of the motor, collect limit feedback, and communicate with the upper system (such as DCS or PLC).

[0003] Currently, most mainstream control cabinets adopt the traditional drawer-type switch structure, which relies on discrete components such as relays, contactors, buttons, indicator lights, and cables for wiring and control. Although this structure is mature and reliable, it has gradually revealed many problems after long-term operation.

[0004] Many components inside the cabinet are aging, structurally redundant, and space is limited, making wiring difficult. Traditional structures have a large number of relays and physical wiring points, and the cabinet space is tight, which is not conducive to module expansion and thermal management. Functions such as remote pulse control, intuitive display of operating status, permission logic switching, and DCS voltage protection are incomplete, posing many potential safety hazards.

[0005] Therefore, there is a need for an electrical control cabinet space integration control loop that can adopt a modular integrated board design, eliminate traditional relays and a large number of cable connections, and build a logically clear, highly integrated, space-optimized, and well-displayed and responsive control system to meet the needs of the current environment. Summary of the Invention

[0006] The purpose of this section is to outline some aspects of the embodiments of the present invention and to briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section, as well as in the abstract and title of the present application, to avoid obscuring the purpose of this section, the abstract and title of the invention. Such simplifications or omissions shall not be used to limit the scope of the present invention.

[0007] Given that many components in the existing cabinets are aging, structurally redundant, and space-constrained, wiring is difficult, traditional structures have a large number of relays and physical wiring points, resulting in limited cabinet space, hindering module expansion and thermal management. Furthermore, functions such as remote pulse control, intuitive display of operating status, access control logic switching, and DCS voltage protection are inadequate, posing numerous safety hazards.

[0008] Therefore, the technical problem to be solved by the present invention is to design an electrical control cabinet space-integrated control loop that can adopt a modular integrated board design, eliminate traditional relays and a large number of cable connections, and construct a logically clear, highly integrated, space-optimized, and well-displayed and feedback-enabled circuit to meet the needs of the current environment.

[0009] To solve the above-mentioned technical problems, the present invention provides the following technical solution: an integrated control loop for an electrical control cabinet, comprising,

[0010] The execution control and drive module receives switching commands and drives the electric actuator and motor through a contactor to realize the opening and closing of the valve;

[0011] The status detection and feedback module converts the actuator operating status into digital and analog signals, and outputs them to the control authority and remote interface module.

[0012] The control permission and remote interface module enables the switching of local and remote control permissions and signal interaction, and supports communication connections with host computers or distributed control systems.

[0013] As an improvement of the present invention,

[0014] The execution control and drive module includes a physical operation panel, a relay adjustment unit, and a coil switching unit;

[0015] The actual operation panel enables local priority switching, command input and fault handling, and is electrically connected to the relay adjustment unit;

[0016] The relay adjustment unit includes a dual relay group with interlocking configuration, receives commands from the actual machine operation panel, and outputs a control coil on / off unit.

[0017] As an improvement of the present invention,

[0018] The coil switching unit includes two contactors connected to the motor assembly to control the forward and reverse energization of the motor assembly, thereby realizing the opening and closing of the valve;

[0019] The coil switching unit uses a 380V coil configuration and is directly driven by the main power supply.

[0020] As an improvement of the present invention,

[0021] The status detection and feedback module includes an actuator switch assembly, which includes a limit auxiliary switch group for detecting the actual position signal of the actuator.

[0022] The actuator switch assembly is electrically connected to the switch mating unit, which includes an input matching circuit connection to provide corresponding signal conversion.

[0023] As an improvement of the present invention,

[0024] The actuator switch assembly connects to the actuator auxiliary assembly, together forming a dual-channel status detection system.

[0025] The actuator switch assembly directly acquires the actuator's on / off and operating status signals and outputs them through normally open / normally closed contacts;

[0026] The actuator auxiliary assembly and the actuator switch assembly are connected in parallel. The output of the actuator auxiliary assembly is connected to the 4-20mA analog feedback terminal and the sliding rheostat unit, respectively.

[0027] As an improvement of the present invention,

[0028] The actuator switch assembly is electrically connected to a complementary switch group, which contains normally open / closed switches with logic opposite to that of the actuator switch assembly.

[0029] Complementary switch groups are connected to the switch coordination unit to perform cross-comparison of output signals, reducing the cost of troubleshooting erroneous signals.

[0030] As an improvement of the present invention,

[0031] The control access and remote interface module includes an integration unit and a logic selection unit;

[0032] The integrated unit gathers and schedules the instruction streams from the execution control and drive module, the status detection and feedback module, and remote input signals;

[0033] The integrated unit connects to the step-down safety unit, which converts the input voltage from 380V to 24V.

[0034] The logic selection unit is electrically connected to the actual machine operation panel to enable selection of short-circuit and point-operated modes.

[0035] As an improvement of the present invention,

[0036] The control permissions and remote interface module also includes a remote display unit;

[0037] The remote display unit is electrically connected to the actual machine operation panel, and receives and displays the execution status signals in real time;

[0038] The actual machine's control panel is connected to a signal receiving unit, which receives control command signals sent from the remote control terminal, ensuring consistent operation and control safety.

[0039] As an improvement of the present invention,

[0040] The motor assembly is electrically connected to the overheat protection unit;

[0041] The overheat protection unit includes a heat-sensitive component and a temperature control trigger, which monitors the temperature rise of the motor assembly in real time during operation.

[0042] The beneficial effects of this invention are as follows: It integrates functions such as switch control, limit feedback, mode selection, and permission switching into the control panel and control board, which greatly reduces the number of physical components and the complexity of internal wiring. The system can realize remote maintenance / pulse control mode switching according to the needs of the site, taking into account the needs of automatic control and manual debugging, improving the system flexibility. Through the matching remote display unit, the operator can monitor the equipment status in real time and realize visual interaction with the DCS system. Attached Figure Description

[0043] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein:

[0044] Figure 1 This is a schematic diagram of the overall architecture of the integrated control loop in the electrical control cabinet of this invention.

[0045] Figure 2 This is a layout diagram of the status detection and feedback module of the integrated control loop in the electrical control cabinet in this invention. Detailed Implementation

[0046] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0047] Example 1

[0048] Reference Figures 1-2 This embodiment provides a space-integrated control loop for an electrical control cabinet.

[0049] The execution control and drive module 1 is located inside the integrated control cabinet. Its main function is to receive switching commands from local buttons, remote DCS systems, or control panels. Upon receiving a command, the execution control and drive module triggers the corresponding set of relays to engage, thereby controlling the closed state of the AC contactor. The AC contactor controls the forward and reverse rotation of the internal motor, thus enabling the opening and closing of the controlled valve.

[0050] To ensure the stability of the control circuit, the execution control and drive module 1 is also connected to a unit for overheat protection, which can monitor the motor operating temperature in real time. When the temperature exceeds the set threshold, the overheat protection unit can immediately disconnect the contactor circuit to prevent damage to the motor.

[0051] The execution control and drive module 1 uses integrated board wiring, which can replace traditional discrete relays and multi-strand wires with miniature relays and pluggable connectors, thereby simplifying the circuit structure and improving the utilization of cabinet space and maintenance convenience.

[0052] The status detection and feedback module 2 monitors the operating status of the electric actuator and converts its status into digital and analog signals for feedback. The status detection and feedback module 2 is implemented through sensors and signal processing circuits integrated on the circuit board. The sensors detect parameters such as the actuator's position, motor current, and operating status (e.g., fully open, fully closed, or intermediate position).

[0053] The parameter signal is converted into a binary signal representing a discrete state by the state detection and feedback module 2. The limit switch in the actuator triggers a digital signal when the valve reaches the fully open or fully closed position. Analog signal: Represents continuous variables, such as actuator stroke or motor load, and is usually output as a 4-20mA signal, compatible with industrial control systems.

[0054] The feedback signal is transmitted to the control authority and remote interface module 3 for further processing. The control authority and remote interface module 3 supports DCS fault display functionality. If the actuator fails to respond to a command, the control authority and remote interface module 3 generates a fault signal, which is displayed on the DCS interface. Operators can quickly identify and handle the problem, improving the system's real-time monitoring capabilities and enhancing operational transparency and reliability.

[0055] The control permission and remote interface module 3 enables the switching between local and remote control permissions and supports signal interaction with the host computer or DCS. The control permission and remote interface module 3 can achieve the above functions through miniature relays and communication interfaces.

[0056] The control authority and remote interface module 3 uses miniature relay switches to replace traditional local / remote changeover switches. Operators can choose local control via miniature buttons and LED indicators on the integrated panel, or remote control via a DCS / PLC system. The miniature relays ensure reliable switching while reducing space requirements.

[0057] The control authority and remote interface module 3 supports bidirectional communication with the DCS, transmitting control commands and feedback signals. Adopting standard industrial protocols, this solution allows selection of Modbus or Profibus to ensure compatibility with existing systems. The control authority and remote interface module 3 receives switching commands from the DCS and transmits them to the execution control and drive module 1. Simultaneously, it transmits signals from the status detection and feedback module 2 to the DCS, providing operators with real-time status updates.

[0058] In this technical solution, the operator selects the remote control mode through the DCS interface. The control authority and remote interface module 3 receives the "open valve" command from the DCS and transmits it to the execution control and drive module 1. The AC contactor is activated, driving the actuator motor to open the valve. The status detection and feedback module 2 monitors the actuator position and generates a feedback signal, such as a 4-20mA signal indicating the valve position, which is ultimately transmitted back to the DCS through the control authority and remote interface module 3.

[0059] This embodiment solves the problems faced by traditional control cabinets through an integrated, efficient, and reliable design. The system's modular architecture, low-pressure operation, and DCS integration improve operational efficiency, safety, and maintainability, making it suitable for industrial applications such as valve control in power plants.

[0060] Example 2

[0061] Reference Figures 1-2 This embodiment is based on the previous embodiment, and differs from the previous embodiment in that:

[0062] The execution control and drive module 1 receives switching commands and drives the electric actuator and its motor to realize the opening and closing of the valve. The execution control and drive module 1 consists of a physical operation panel 11, a relay adjustment unit 12, a coil switching unit 13, and a motor assembly 14, all integrated on a single circuit board, replacing the complex wiring and relays of traditional drawer-type switch cabinets.

[0063] The actual machine operation panel 11 is the core interface for local control, integrated on the circuit board, and uses micro buttons and LED indicators.

[0064] The actual operation panel 11 is electrically connected to the logic selection unit 32, allowing the operator to select between local and remote control modes. In local mode, panel commands take precedence over DCS remote commands, ensuring flexibility in on-site operation. For example, if the operator presses the "Start" button, the panel directly sends a signal to the relay adjustment unit 12 without waiting for DCS confirmation.

[0065] The actual machine operation panel 11 is equipped with miniature touch buttons for inputting "on," "off," or "stop" commands. These buttons are designed as low-power electronic switches, occupying only 1 / 3 the space of traditional mechanical buttons. The buttons are connected to the relay adjustment unit 12 via a signal bus, ensuring fast and reliable command transmission. LED indicators on the actual machine operation panel 11 display the actuator status: green indicates normal operation, and red indicates a fault. When the status detection and feedback module 2 detects an abnormality, the actual machine operation panel 11 receives the fault signal via electrical connection, illuminating the red LED to prompt the operator to perform maintenance. The LEDs feature a low-power design, consuming only 1 / 5 the power of traditional indicator lights, extending their lifespan.

[0066] The relay adjustment unit 12 includes an interlocked dual relay group that receives commands from the actual operation panel 11 and outputs them to the coil switching unit 13. The dual relay group uses miniature relays and uses interlocking logic to prevent conflicting commands. When an "open" command activates one relay, the interlocking mechanism ensures that the "close" relay remains open, preventing the valve from receiving open / close signals simultaneously.

[0067] The dual relay group is integrated on the circuit board, reducing its size by 50% compared to traditional relays and decreasing the need for wiring within the cabinet. Each relay supports at least 100,000 high-frequency switching operations, ensuring long-term operational reliability. The instruction processing flow is as follows: When the actual machine operation panel 11 sends an "open" signal, the dual relay group closes the corresponding relay, outputting a control signal to the coil on / off unit 13, triggering the valve opening action.

[0068] The coil switching unit 13 includes dual contactors connected to the motor assembly 14 to control the forward and reverse energization of the motor to open and close the valve. The dual contactors use a 380V coil configuration, directly powered by the mains supply, suitable for the high-voltage requirements of industrial environments. The contactors utilize highly reliable industrial-grade components, with a rated current supporting the maximum load of the motor assembly 14 (e.g., 10A), ensuring stable operation.

[0069] The motor assembly 14 includes the motor of the electric actuator, which provides the mechanical power for opening and closing the valve. Dual contactors control the forward (opening) and reverse (closing) energization respectively. When the operator inputs the "open" command, the relay adjustment unit 12 activates the forward contactor, causing the motor assembly 14 to rotate forward and drive the valve to open. The system can support up to 55 actuators, each controlled by an independent coil switching unit 13, ensuring precise operation.

[0070] The status detection and feedback module 2 monitors the operating status of the actuator, generates digital and analog signals, and feeds them back to the control authority and remote interface module 3. The status detection and feedback module 2 consists of an actuator switch assembly 21, an actuator auxiliary assembly 22, a complementary switch group 23, and a switch coordination unit 211, all integrated on a circuit board.

[0071] The actuator switch assembly 21 includes a limit auxiliary switch group that detects the actual position signal of the actuator (such as fully open, fully closed, or intermediate position). The limit switches use normally open / normally closed contacts; for example, when the valve reaches the fully open position, the normally open contact closes, generating a "fully open" signal. The signal is processed by the switch coordination unit 211, which includes an input matching circuit that converts the raw signal from the limit switches into a standardized switching signal.

[0072] The actuator auxiliary assembly 22 is connected in parallel with the actuator switch assembly 21 to form a dual-channel status detection system, improving the reliability of signal acquisition. The auxiliary assembly 22 includes additional sensors to monitor the continuous status of the actuator (such as stroke ratio or motor load). Its output is connected to a 4-20mA analog feedback terminal to generate a continuous signal indicating the valve opening degree.

[0073] The sliding rheostat unit 221 is electrically connected to the auxiliary assembly 22. It detects the mechanical position of the actuator through the sliding resistor, generates a resistance signal proportional to the position, and then converts it into a 4-20mA analog output through a signal conditioning circuit. The dual-channel design ensures that even if one channel fails, the other channel can still provide reliable feedback. The analog signal is transmitted to the DCS via cable for real-time monitoring by operators.

[0074] The complementary switch group 23 is electrically connected to the actuator switch assembly 21 and includes normally open / normally closed switch groups with opposite logic. If the limit switch of the actuator switch assembly 21 has a normally open contact, the complementary switch group 23 provides a normally closed contact. The complementary switch group 23 is connected to the switch coordination unit 211, and the output signal is cross-compared to reduce the cost of troubleshooting erroneous signals.

[0075] If the actuator switch assembly 21 falsely reports a "fully open" signal, the normally closed signal of the complementary switch group 23 can be used for verification, reducing the risk of misjudgment and improving maintenance efficiency.

[0076] Example 3

[0077] Reference Figures 1-2 This embodiment is based on the previous embodiment, and differs from the previous embodiment in that:

[0078] The control authority and remote interface module 3 is responsible for switching between local and remote control authority and for signal interaction with the DCS. The control authority and remote interface module 3 includes an integration unit 31, a logic selection unit 32, a remote display unit 33, and a signal receiving unit 34, realizing remote / local switching and DCS communication functions.

[0079] The integrated unit 31 gathers the instruction stream from the execution control and drive module 1, the status detection and feedback module 2, and remote input signals, acting as a central scheduling unit. Based on an integrated board design, the integrated unit 31 coordinates the operation of each module via a signal bus, receives remote instructions from the DCS, distributes them to the execution control and drive module 1, or transmits status signals to the DCS.

[0080] The step-down safety unit 311 includes a 24V transformer that converts 380V AC voltage to 24V DC voltage to supply the control circuit, preventing damage to the DCS module from leakage or cross-circuiting. The transformer is integrated with the circuit board via a plug-in connector for easy maintenance. The logic selection unit 32 is electrically connected to the actual operation panel 11, supporting short-circuit and inching / continuous operation mode selection. Short-circuit mode allows for direct local control, inching mode supports pulse operation, and continuous mode supports long-term signal drive. The logic selection unit 32 is implemented using miniature relays, ensuring reliable switching and a small footprint.

[0081] The remote display unit 33 is electrically connected to the actual machine operation panel 11, receiving and displaying the actuator status (such as valve position or fault) in real time through the DCS interface. Local LED indicators synchronously display the status for convenient on-site monitoring. The signal receiving unit 34 receives control commands sent by the DCS, ensuring operational consistency and safety. The overheat protection unit 4 is electrically connected to the motor assembly 14 and includes a heat-sensitive component, a thermistor, and a temperature control trigger, monitoring the motor temperature rise in real time. If the temperature exceeds 80°C, the trigger disconnects the motor power supply and sends a fault signal to the DCS, protecting the motor and extending its lifespan.

[0082] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A space-integrated control loop for an electrical control cabinet, characterized in that: include, The execution control and drive module (1) receives the switch command and drives the electric actuator and motor through the contactor to realize the opening and closing of the valve; The status detection and feedback module (2) converts the actuator operating condition into digital and analog signals and outputs them into the control authority and remote interface module (3). The control permission and remote interface module (3) enables the switching of local and remote control permissions and signal interaction, and supports communication connection with the host computer or distributed control system.

2. The integrated control loop for electrical control cabinets according to claim 1, characterized in that: The execution control and drive module (1) includes a physical operation panel (11), a relay adjustment unit (12), and a coil switching unit (13); The actual operation panel (11) realizes local priority switching, command input and fault handling, and is electrically connected to the relay adjustment unit (12); The relay adjustment unit (12) includes a dual relay group with interlocking configuration, receives instructions from the actual operation panel (11), and outputs a control coil on / off unit (13).

3. The integrated control loop for the electrical control cabinet according to claim 2, characterized in that: The coil switching unit (13) includes a double contactor connected to the motor assembly (14) to control the motor assembly (14) to be energized in both directions, thereby realizing the opening and closing of the valve; The coil switching unit (13) adopts a 380V coil configuration and is directly driven by the main power supply.

4. The integrated control circuit for the electrical control cabinet according to any one of claims 1 to 3, characterized in that: The status detection and feedback module (2) includes an actuator switch assembly (21), which includes a limit auxiliary switch group for detecting the actual position signal of the actuator. The actuator switch assembly (21) is electrically connected to the switch coordination unit (211), which includes an input matching circuit connection to provide corresponding signal conversion.

5. The integrated control loop for the electrical control cabinet according to claim 4, characterized in that: The actuator switch assembly (21) is connected to the actuator auxiliary assembly (22) to form a dual-channel status detection system. The actuator switch assembly (21) directly acquires the on, off, and running status signals of the actuator and outputs them through normally open / normally closed contacts; The actuator auxiliary assembly (22) and the actuator switch assembly (21) are connected in parallel. The output terminal of the actuator auxiliary assembly (22) is connected to the 4-20mA analog feedback terminal and the sliding rheostat unit (221) respectively.

6. The integrated control loop for the electrical control cabinet according to claim 5, characterized in that: The actuator switch assembly (21) is electrically connected to the complementary switch group (23), and the complementary switch group (23) is provided with normally open / closed switches that are logically opposite to those of the actuator switch assembly (21); The complementary switch group (23) is connected to the switch coordination unit (211) to perform cross-comparison of output signals, thereby reducing the cost of troubleshooting erroneous signals.

7. The integrated control loop for electrical control cabinets according to claim 6, characterized in that: The control authority and remote interface module (3) includes an integration unit (31) and a logic selection unit (32); The integrated unit (31) gathers and schedules the instruction stream of the execution control and drive module (1), the status detection and feedback module (2), and the remote input signal; The integrated unit (31) is connected to the step-down safety unit (311), which converts the input voltage of 380V to 24V; The logic selection unit (32) is electrically connected to the actual machine operation panel (11) to realize the selection of short-circuit and point-operated conditions.

8. The integrated control circuit for the electrical control cabinet according to claim 7, characterized in that: The control authority and remote interface module (3) also includes a remote display unit (33); The remote display unit (33) is electrically connected to the actual machine operation panel (11) to receive and display the execution status signal in real time; The actual machine operation panel (11) is connected to the signal receiving unit (34). The signal receiving unit (34) receives the control command signal sent by the remote control terminal to ensure consistent operation and control safety.

9. The integrated control circuit for the electrical control cabinet according to claim 8, characterized in that: The motor assembly (14) is electrically connected to the overheat protection unit (4); The overheat protection unit (4) includes a heat-sensitive component and a temperature control trigger, which detects the temperature rise of the motor assembly (14) during operation in real time.

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