Real-time monitoring device and monitoring method applied to state of insulator of electric control cabinet

Abstract

The invention provides a real-time monitoring device and method applied to the state of an insulator of an electric control cabinet. The real-time monitoring method comprises the following steps that the current environment temperature detected by a controller is obtained; whether the current environment temperature is lower than a preset temperature threshold value or not is judged, and when it is monitored that the environment temperature is lower than the preset temperature threshold value, an insulator in the electrical cabinet works normally; when the environment temperature is higher than the critical temperature, a fan is started for cooling, and when the environment temperature is higher than a preset temperature threshold value and lower than the critical temperature, the magnitude IR of leakage current is calculated; the leakage current IR of the corresponding insulator under different air humidity conditions is calculated; whether the leakage current IR reaches the critical value of the safety leakage current Is or not is judged, and alarm information is given out according to the judgment result. Therefore, long-term safe operation of the electric control cabinet in special environments such as ships and the like is guaranteed through the synergistic effect of active regulation and control of temperature and humidity, accurate monitoring of leakage current and timely alarm of abnormity.

Description

Technical Field

[0001] This invention relates to the field of real-time insulator monitoring, and more specifically, to a device and method for real-time monitoring of the status of insulators in electrical control cabinets suitable for special environments such as ships with drastic temperature and humidity fluctuations and high salt spray concentrations. Background Technology

[0002] As the core component for achieving electrical insulation and structural fixation, the performance stability of insulators in electrical control cabinets directly determines the operational safety of the equipment. On the one hand, insulators must rely on their own insulation properties to isolate conductors at different potentials or conductors from grounding components, blocking unexpected current leakage paths and preventing short-circuit accidents. On the other hand, insulators must also provide mechanical fixation for electronic components within the cabinet, ensuring stable component installation positions and the ability to withstand long-term mechanical loads during equipment operation without structural failure. However, the marine environment of ships poses a significant threat to the performance of electrical control cabinet insulators: Firstly, the large diurnal temperature range and high relative humidity in the marine environment easily lead to condensation on the insulator surface, damaging its surface insulation layer. Secondly, the high salinity of seawater increases the concentration of salt spray in the air; salt spray particles adhere to the insulator surface, gradually forming conductive channels and significantly reducing the insulator's insulation resistance. The combined effect of these factors can lead to a significant increase in insulator leakage current, potentially causing flashover faults and resulting in the shutdown of the electrical control cabinet. In existing technologies, the protection of insulators largely relies on periodic manual cleaning and maintenance. However, shipboard electrical control cabinets are often installed in confined and inaccessible areas of cabins. Frequent shutdowns for maintenance are not only difficult to operate and costly, but also fail to provide real-time dynamic protection. When temperature and humidity change abruptly or salt spray concentration rises for a short period, manual maintenance cannot respond in time, and the risk of failure remains. Therefore, there is an urgent need for a device that can monitor in real time, actively control, and automatically alarm to address the impact of temperature and humidity on insulators in shipboard environments, reduce reliance on manual maintenance, and reduce the probability of insulation failures from the source. Summary of the Invention

[0003] In view of this, the present invention aims to propose a real-time monitoring device and method for the status of insulators in electrical control cabinets, so as to solve the problems in the prior art where the insulators of electrical control cabinets are greatly affected by temperature and humidity in marine environments, rely on manual maintenance, and have a high probability of failure.

[0004] To achieve the above objectives, the technical solution of the present invention is implemented as follows: A method for real-time monitoring of the condition of insulators in electrical control cabinets includes the following steps: S100: Obtain the current ambient temperature detected by the controller; S200. Determine if the current ambient temperature is lower than the preset temperature threshold. If the ambient temperature is detected to be lower than the preset temperature threshold, the insulators inside the electrical cabinet will operate normally. If the ambient temperature is higher than the critical temperature, turn on the fan to cool down. If the ambient temperature is higher than the preset temperature threshold but lower than the critical temperature, calculate the leakage current I. R ; S300. Calculate the leakage current I of the insulator under different air humidity conditions. R ; S400, Determine leakage current I R Has the safe leakage current I been reached? s The threshold value is determined, and an alarm message is given based on the judgment result.

[0005] Furthermore, the preset temperature threshold is lower than the critical temperature.

[0006] Furthermore, leakage current I R The calculation formula is: I 100 =a R I R I 100 The saturation leakage current of the insulator is measured at an ambient temperature of 20~25℃ and an air humidity of 100%. a R is a coefficient.

[0007] Furthermore, coefficients a R The method for determining this is: real-time acquisition of air humidity saturation. H R Then, a system of equations is formed from the following formulas, and the coefficients can be solved. a R .

[0008] a R =-1771.5H R 2 +5030.8H R 2 -4769.3H R +1511 in H R Greater than 80%.

[0009] Furthermore, step S300 includes activating the control device when the air humidity is greater than a preset humidity threshold, and calculating the leakage current I of the insulator under different air humidity conditions. R.

[0010] Furthermore, the preset humidity threshold can be set to 70-85% as needed.

[0011] Furthermore, determine the leakage current I. R Is it close to the safe leakage current I? s The criterion for determining the critical value is the leakage current I. R Is it equal to ɛI? S When the ambient temperature is between 20 and 25°C, if the leakage current I... R Not reached ɛI S To determine if the insulator is functioning normally; if the leakage current I... R Reaching ɛI S When the leakage current is determined to be close to the safe leakage current, the controller outputs an alarm message through the alarm device.

[0012] Furthermore, ɛ is 85-98%.

[0013] Compared with existing technologies, the real-time monitoring method for the status of insulators in electrical control cabinets described in this invention has the following advantages: This device solves the problems of insulation degradation and difficulty in early warning of faults in electrical control cabinet insulators due to environmental factors. Composed of a controller, high-precision temperature and humidity sensors, and a fan, it forms a closed-loop system of "monitoring-control-alarm." Using 25℃ as the temperature threshold, the fan stabilizes the temperature. When humidity exceeds 80%, the real-time leakage current of the insulator is calculated using a correction coefficient formula and compared to the safety threshold of 95% to determine the status. If the current exceeds the limit, audible and visual alarms, on-screen warnings, and remote notifications are triggered simultaneously. The product boasts a high degree of automation, providing real-time protection for insulators, reducing the insulation failure rate of electrical control cabinets, and ensuring the safe operation of power systems in scenarios such as ships.

[0014] Thus, through the synergistic effect of active temperature and humidity control, precise leakage current monitoring, and timely alarm for abnormalities, the long-term safe operation of the electrical control cabinet in special environments such as ships is ensured.

[0015] The present invention also provides a real-time monitoring device for the status of insulators in electrical control cabinets. Using the real-time monitoring method described above, the real-time monitoring device includes a controller, a temperature and humidity sensor, a fan, an alarm device, a display screen, and a communication module. The controller is connected to the temperature and humidity sensor, the fan, the alarm device, and the display screen.

[0016] Furthermore, the controller is configured as a PLC controller.

[0017] The advantages of the real-time monitoring device and the real-time monitoring method compared to the prior art are the same, and will not be repeated here. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the electrical control cabinet insulator status monitoring device according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the insulator status monitoring method for electrical control cabinets according to an embodiment of the present invention. Detailed Implementation

[0019] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0020] Leakage current refers to the current that flows through the surrounding medium or insulating surface between insulated metal parts in an electrical system, or between a live part and a grounded part, when no fault voltage is applied. Leakage current is essentially the current flowing through the insulating parts of an electrical circuit or equipment when there is no fault and no applied voltage. Therefore, it is one of the important indicators of the insulation quality of electrical appliances and a key indicator of product safety performance. Secondly, shipboard electrical control cabinets are limited by installation space, making frequent operation and cleaning inconvenient. Furthermore, the environmental parameters inside the cabinet (temperature, humidity, salt density on the insulator surface) are dynamically changing—in the marine environment, the salt density on the insulator surface increases significantly with prolonged operation, further exacerbating the increasing trend of leakage current. Existing technologies cannot achieve real-time intervention in this dynamic environment. This invention aims to solve this technical pain point and achieve linked control of environmental parameters and insulator status.

[0021] To address the aforementioned technical problems, this invention provides a real-time monitoring method for the status of insulators in electrical control cabinets, comprising the following steps: S100: Obtain the current ambient temperature detected by the controller; In practical engineering, for safety reasons, electrical cabinets are grounded. Components inside the cabinet that cannot be grounded must be fixed by insulators. Insulators are used to ensure that the electronic component is not grounded. If the insulator fails, leakage current will occur. Generally, the safe leakage current of the component is set to I. s If the leakage current of an insulator is detected to be close to or greater than the safe leakage current, it indicates that the insulator may have failed and staff should be alerted to clean the insulator. Therefore, it is necessary to monitor the real-time leakage current of the insulator in order to obtain the status of the insulator in a timely and effective manner.

[0022] S200: Determine whether the current ambient temperature is lower than the preset temperature threshold; The preset temperature threshold is set to 20~25℃, preferably 20℃.

[0023] When the ambient temperature is low and the ambient temperature is detected to be below the preset temperature threshold, the corresponding ambient humidity saturation also decreases. The maximum leakage current of the insulator is generally very small and will not cause adverse effects, so it can be ignored. At this time, the insulators inside the electrical cabinet can work normally.

[0024] Based on the actual situation, when the ambient temperature is higher than 25℃, the leakage current of the insulator will increase as the ambient humidity saturation increases. Therefore, the temperature inside the cabinet is taken as 22.5℃ as the critical temperature for regulating the ambient humidity. 22.5℃ is set as the critical temperature for turning on the fan inside the cabinet. The temperature is maintained between 20~25℃ by turning on the fan inside the cabinet.

[0025] In this embodiment, under normal ambient temperature of 20~25℃ and air humidity of 100%, the saturation leakage current of the insulator is measured to be I. 100 .

[0026] The leakage current of insulators is affected by the environment, with air humidity having the greatest impact. Multiple experiments have shown that the correlation between air humidity and leakage current is greater than 90%, especially at higher humidity levels. When the air humidity does not exceed a preset humidity threshold, the maximum leakage current is generally very small and has no adverse effect, therefore it can be ignored. When the air humidity exceeds the preset humidity threshold, the leakage current I of the corresponding insulator needs to be calculated based on the specific air humidity conditions. R .

[0027] The preset humidity threshold can be set to 70-85% as needed. Preferably, the preset humidity threshold can be set to 80%. When the air humidity is less than or equal to 80%, the maximum leakage current is generally very small and will not have an impact, so it can be ignored. When the air humidity is greater than 80%, the control device is activated, and the leakage current I of the insulator under different air humidity conditions is calculated. R .

[0028] S300. Calculate the leakage current I of the insulator under different air humidity conditions. R The leakage current I R The calculation formula is: I 100 =a R I R In the above formula, I 100 The saturation leakage current of the insulator is measured at an ambient temperature of 20~25℃ and an air humidity of 100%. a R For coefficients, coefficients aR The method for determining this is: real-time acquisition of air humidity saturation. H R Then, a system of equations is formed from the following formulas, and the coefficients can be solved. a R .

[0029] a R =-1771.5H R 2 +5030.8H R 2 -4769.3H R +1511 in H R Greater than 80%.

[0030] S400, Determine leakage current I R Has the safe leakage current I been reached? s The critical value.

[0031] Determine the leakage current I R Is it close to the safe leakage current I? s The criterion for determining the critical value is the leakage current I. R Is it equal to ɛI? S When the ambient temperature is between 20 and 25°C, if the leakage current I... R Not reached ɛI S This indicates that the insulator is functioning normally. Conversely, if the leakage current I... R Reaching ɛI S If the leakage current is determined to be close to the safe leakage current, the controller will output an alarm message through the alarm device, issue an audible and visual alarm, and display it on the crew's operating computer screen, reminding the staff that there is an abnormality in the insulators inside the electrical cabinet, and that it is necessary to check it in time, open the electrical cabinet and clean the insulators to avoid causing greater loss of life and property.

[0032] Where ɛ = 85~98%, preferably, ɛ is set to 95%.

[0033] As one embodiment of the present invention, a real-time monitoring device for the status of insulators in an electrical control cabinet is also provided, comprising a controller, a high-precision temperature and humidity sensor, a fan, an alarm device, a display screen, and a communication module, wherein: A temperature and humidity sensor is used to monitor the temperature and humidity of the environment and transmit the monitored information to the controller. The controller is connected to the fan and the alarm. The controller receives the temperature and humidity information monitored by the temperature and humidity sensor and controls the operation and start / stop of the alarm and the fan based on the received temperature and humidity information. Preferably, the controller is a PLC controller.

[0034] The fan is connected to the controller and controls the fan to turn on and off according to the controller's instructions in order to dissipate heat from inside the electrical cabinet.

[0035] The display screen is set up as an industrial computer, which can be a portable tablet computer. The display screen is connected to the controller and is used to display the information received by the controller and the instructions issued by the controller on the display screen.

[0036] The communication module acts as a bridge for communication between various components, enabling the transmission of data and information between different components.

[0037] This invention provides a real-time monitoring device and method for the status of insulators in electrical control cabinets, overcoming the pain point of inaccurate current calculation caused by temperature interference and improving monitoring accuracy. It solves the problem of inconvenient operation and maintenance of ship electrical control cabinets, achieving full-process automation and reducing labor costs and the risk of missed inspections. Specifically, this technology has strong environmental adaptability: for the high humidity and high salt spray environment of ships, it achieves dynamic monitoring of insulator status through temperature closed-loop control and humidity-related leakage current calculation, solving the problem of low monitoring accuracy of traditional devices in special environments; high degree of automation: no manual intervention is required throughout the process, from temperature and humidity acquisition and parameter calculation to abnormal alarms, all are automated, significantly reducing manual maintenance costs and avoiding failures caused by untimely manual inspections; strong early warning timeliness: with 95% I... S As an early warning threshold, the alarm is triggered before leakage current exceeds the limit, allowing staff time to handle the fault and achieving "prevention before the event," effectively reducing the probability of insulation failure in the electrical control cabinet. Thus, through the synergistic effect of active temperature and humidity control, precise leakage current monitoring, and timely alarm for abnormalities, the long-term safe operation of the electrical control cabinet in special environments such as ships is ensured.

[0038] While the present invention has been disclosed above, it is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A real-time monitoring method applied to the state of an insulator of an electric control cabinet, characterized in that, The method comprises the following steps: S100, acquiring a current environment temperature detected by a controller; S200, judge whether the current environment temperature is lower than the preset temperature threshold value, when it is monitored that the environment temperature is lower than the preset temperature threshold value, the internal insulator of the electrical cabinet works normally; when the environment temperature is higher than the critical temperature, the fan is started to cool down; when the environment temperature is higher than the preset temperature threshold value and lower than the critical temperature, the leakage current size I is calculated R ; S300, calculate the leakage current size I of the corresponding insulator under different air humidity conditions R ; S400, judging whether the leakage current I R reaches a critical value of the safety leakage current I s , and giving an alarm information according to the judging result.

2. The real-time monitoring method of claim 1, wherein, The preset temperature threshold is less than the critical temperature.

3. The real-time monitoring method of claim 1, wherein, Leakage current I R The calculation formula is: I 100 = a R I R I 100 The saturation leakage current of the insulator is measured at a daily temperature of 20-25°C and an air humidity of 100%;a R is a coefficient.

4. The real-time monitoring method of claim 3, wherein, Coefficient a R The determination method of the coefficient a is: real-time acquisition of air humidity saturation H R Then the equation group is constituted by the following formula, and then the coefficient a is solved R； ； wherein H R greater than 80%.

5. The real-time monitoring method of claim 1, wherein, Step S300 includes starting the regulating device when the air humidity is greater than a preset humidity threshold, and calculating the leakage current size I of the insulator under different air humidity conditions R .

6. The real-time monitoring method of claim 5, wherein, The preset humidity threshold is set to 70-85% as needed.

7. The real-time monitoring method of claim 1, wherein, determining whether the leakage current I R is close to the safety leakage current I s The determination index of whether the critical value of the leakage current I R is equal to ɛI S When the ambient temperature is 20-25℃, if the leakage current I R does not reach ɛI S , it is determined that the insulator can work normally; if the leakage current I R reaches ɛI S , it is determined that the leakage current is close to the safety leakage current, and the controller outputs alarm information through the alarm.

8. The real-time monitoring method of claim 7, wherein, ɛ is 85-98%.

9. A real-time monitoring device applied to the insulation substate of an electric control cabinet, characterized in that, The real-time monitoring device comprises a controller, a temperature and humidity sensor, a fan, an alarm device, a display screen and a communication module, and the controller is connected with the temperature and humidity sensor, the fan, the alarm device and the display screen.

10. The real-time monitoring device of claim 9, wherein, The controller is a PLC controller.

Images