Activated carbon box monitoring system based on PLC control

Abstract

The invention relates to the technical field of industrial process monitoring, in particular to an activated carbon box monitoring system based on PLC control. The activated carbon box monitoring system based on PLC control comprises a control system, a sensor assembly arranged in an activated carbon box and a man-machine interaction interface, the input end of the control system is electrically connected with the sensor assembly, and the output end of the control system is electrically connected with the man-machine interaction interface; the input end is used for receiving a sensor signal of a sensor assembly arranged in the activated carbon box; the control system processes the sensor signal to generate operation data information and transmits the operation data information to the human-computer interaction interface through the output end; the man-machine interaction interface stores and displays the operation data information, and outputs alarm information based on the operation data information; therefore, the abnormal working condition is recognized, and finally, the abnormal state is prompted in time through man-machine interaction.

Description

Technical Field

[0001] This invention relates to the field of industrial process monitoring technology, specifically to a PLC-controlled activated carbon box monitoring system. Background Technology

[0002] Activated carbon boxes, as an important component of waste gas treatment systems, are widely used in industries such as chemical engineering, spraying, and electronics manufacturing. In existing technologies, activated carbon boxes typically use a fan to directly blow waste gas containing pollutants, and the waste gas is then discharged after passing through the activated carbon adsorption layer, thereby achieving the purification treatment of the waste gas.

[0003] In electric locomotive systems, activated carbon boxes are typically used as passive treatment devices. Their operation depends primarily on the fan's condition and the activated carbon filling status. Real-time monitoring and feedback control of the internal operating parameters of the activated carbon box are lacking during system operation. Current technology involves directly supplying air to the activated carbon box, with purified exhaust gas exiting after passing through it. However, there is no monitoring or alarm function for the temperature and pressure difference between the inlet and outlet sides during operation. If the activated carbon box becomes clogged or overheats, it is highly susceptible to failure and fire.

[0004] Therefore, it is urgent to improve the existing technical solutions to enhance the monitoring of activated carbon boxes. Summary of the Invention

[0005] The purpose of this invention is to: compared with existing technical solutions, To achieve the above-mentioned objectives, this application implements the following technical solution: A PLC-controlled activated carbon box monitoring system includes: a control system, sensor components installed in the activated carbon box, and a human-machine interface. The input terminal of the control system is electrically connected to the sensor assembly, and the output terminal of the control system is electrically connected to the human-machine interface. The input terminal is used to receive sensor signals from the sensor assembly installed in the activated carbon box. The control system processes the sensor signals to generate operating data information and transmits it to the human-machine interface through the output terminal. The human-computer interaction interface stores and displays operational data information, and outputs alarm information based on the operational data information.

[0006] The above technical solution produces the following technical effects: The system described in this application achieves real-time monitoring and alarm functions for the activated carbon box's operating status by installing sensor components within the box and incorporating a PLC control system and a human-machine interface. Specifically, real-time acquisition of temperature and inlet / outlet pressure difference during the activated carbon box's operation allows for the acquisition of key parameters reflecting its operating status from the source. Furthermore, this application uses the PLC control system to process the acquired sensor signals, converting them into corresponding operational data and performing logical judgments on this data to identify abnormal operating conditions. Finally, timely alerts for abnormal states are provided through the human-machine interface.

[0007] As a further improvement to the PLC-controlled activated carbon box monitoring system of this application, the sensor assembly includes at least one temperature sensor and at least one differential pressure sensor. The temperature sensor is used to detect the temperature inside the activated carbon box and outputs a temperature signal to the input terminal in the form of an analog signal. The differential pressure sensor is used to detect the pressure difference between the inlet and outlet of the activated carbon box and outputs the differential pressure signal to the input terminal in the form of an analog signal.

[0008] As a further improvement to the activated carbon box monitoring system based on PLC control of this application, the control system is a PLC control system. The control system performs engineering quantity conversion and logic processing on the temperature signal and the differential pressure signal to generate temperature operation data information and differential pressure operation data information respectively. Temperature and differential pressure operating data are transmitted to the human-machine interface via the output terminal.

[0009] As a further improvement to the activated carbon box monitoring system based on PLC control of this application, the control system collects temperature signals and converts the temperature signals from analog signals to temperature engineering signals, matches the temperature engineering signals with temperature thresholds, and outputs temperature alarm bit signals on the human-machine interface when the temperature engineering signals exceed the temperature thresholds. The temperature alarm bit signals are included in the temperature operation data information. The control system acquires differential pressure signals and converts them from analog signals to differential pressure engineering signals. It then matches these signals with differential pressure thresholds. When a differential pressure engineering signal exceeds the threshold, it outputs a differential pressure alarm signal to the human-machine interface. The differential pressure alarm signal is included in the differential pressure operation data information.

[0010] As a further improvement to the PLC-controlled activated carbon box monitoring system of this application, both the temperature threshold and the differential pressure threshold are configurable parameters and are written into the control system through the human-machine interface.

[0011] As a further improvement to the PLC-based activated carbon box monitoring system of this application, the control system adopts an external AC power supply as the power input. After passing through a short-circuit protector, the power supply enters the switching power supply module, which converts 220V AC power into 24V DC power. The 24V DC power is used to power the control system, sensor components and human-machine interface.

[0012] As a further improvement to the PLC-controlled activated carbon box monitoring system of this application, the sensor assembly is connected to the input terminal via a terminal block. Attached Figure Description

[0013] Figure 1 This is a system overall block diagram of the activated carbon box monitoring system based on PLC control of the present invention; Figure 2 This is the electrical schematic diagram of the activated carbon box monitoring system based on PLC control of the present invention; Figure 3 This is a schematic diagram of the PLC calling program for the activated carbon box monitoring system based on PLC control according to the present invention. Figure 4 This is a schematic diagram of the PLC analog quantity acquisition program for the PLC-controlled activated carbon box monitoring system of the present invention. Figure 5 This is the data display interface of the human-machine interface in the PLC-controlled activated carbon box monitoring system of the present invention; Figure 6 This is one of the parameter setting interfaces of the human-machine interface in the PLC-controlled activated carbon box monitoring system of the present invention; Figure 7 This is the data recording interface of the human-machine interface in the PLC-controlled activated carbon box monitoring system of the present invention; Figure 8 This is the alarm recording interface of the human-machine interface in the PLC-controlled activated carbon box monitoring system of the present invention; Figure 9 This is the data export interface of the human-machine interface in the PLC-controlled activated carbon box monitoring system of the present invention; Figure 10 This is the carbon replacement recording interface of the human-machine interface in the PLC-controlled activated carbon box monitoring system of the present invention; Tag name: 1 - Control system; 2 - Sensor Components; 3 - Human-computer interaction interface; Detailed Implementation

[0014] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0015] The following detailed description is exemplary and intended to provide further detailed explanation of the invention. Unless otherwise specified, all technical terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this invention is for describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention.

[0016] Example 1 This application recognizes that existing activated carbon box systems typically do not monitor the temperature inside the box or in the gas passages in real time. When the exhaust gas temperature rises abnormally or localized high temperatures occur due to exothermic adsorption reactions, the system cannot obtain temperature change information in a timely manner, posing a risk of activated carbon spontaneous combustion or fire. Furthermore, existing systems do not monitor the pressure difference between the inlet and outlet of the activated carbon box. As activated carbon adsorption becomes saturated, dust accumulates, or the packing material compacts, gas resistance gradually increases, and the fan load rises. However, the system cannot determine whether the activated carbon box is blocked or malfunctioning based on pressure difference changes, leading to delayed maintenance. These two situations prevent the system from accurately identifying and handling corresponding abnormalities. To solve these technical problems, this application designs a PLC-controlled activated carbon box monitoring system.

[0017] Specifically, such as Figure 1-3 The activated carbon box monitoring system based on PLC control of this application includes: a control system 1, a sensor assembly 2 installed in the activated carbon box, and a human-machine interface 3. The input terminal of the control system 1 is electrically connected to the sensor assembly 2, and the output terminal of the control system 1 is electrically connected to the human-machine interface 3. The input terminal is used to receive sensor signals from the sensor assembly 2 installed in the activated carbon box. The control system 1 processes the sensor signals to generate operating data information and transmits it to the human-machine interface 3 through the output terminal.

[0018] Furthermore, sensor assembly 2 includes at least one temperature sensor and at least one differential pressure sensor; A temperature sensor detects the temperature inside the activated carbon box and outputs a temperature signal to the input terminal in the form of an analog signal. A differential pressure sensor detects the pressure difference between the inlet and outlet of the activated carbon box and outputs a differential pressure signal to the input terminal in the form of an analog signal. Control system 1 is a PLC control system 1. Control system 1 performs engineering quantity conversion and logic processing on the temperature signal and differential pressure signal respectively to generate temperature operation data information and differential pressure operation data information. The temperature operation data information and differential pressure operation data information are transmitted to the human-machine interface 3 through the output terminal.

[0019] Furthermore, the control system 1 of this application acquires temperature signals and converts them from analog signals to temperature engineering signals. It then matches the temperature engineering signals with a temperature threshold. When the temperature engineering signals exceed the temperature threshold, it outputs a temperature alarm signal on the human-machine interface 3. The temperature alarm signal is included in the temperature operation data information. The control system 1 also acquires differential pressure signals and converts them from analog signals to differential pressure engineering signals. It matches the differential pressure engineering signals with a differential pressure threshold. When the differential pressure engineering signals exceed the differential pressure threshold, it outputs a differential pressure alarm signal on the human-machine interface 3. The differential pressure alarm signal is included in the differential pressure operation data information.

[0020] Specifically, such as Figure 3 As shown, the PLC program segment in this application uses SM0.0 (Always_On) as the normally open enable, therefore the PLC will execute three blocks sequentially for each scan: FC_AI: Collects analog quantities and converts them into engineering quantities (actual values ​​of temperature / pressure difference). FT_TIME: Generates time conditions such as "time tick / sampling period / delay" (for storage and alarm delay). FC_ALM: Compares the workload with the threshold and outputs an alarm signal to the human-machine interface 3.

[0021] Furthermore, such as Figure 4 As shown, the temperature and differential pressure sensors used in this application typically have a 4–20mA output. After being input as analog signals, they are converted into a "raw digital quantity" (AD counter) in the PLC system. Figure 4 In this application, for example, channel 1-AIW16 (e.g., temperature 1 or pressure difference 1) and channel 2-AIW18 (e.g., temperature 2 or pressure difference 2) are used. These two AIW values ​​are essentially "digital results of current magnitude", not ℃ or Pa.

[0022] Furthermore, in Figure 4 In code segment 2 shown, the function block of this application is S_ITR (specifically, a linear transformation), and the other input terminals are: Input: AIW16 / AIW18 (the original input in the examples mentioned above): ISH / ISL: Input upper / lower limits (corresponding to the raw counts of 20mA and 4mA), specifically ISH = 27648, ISL = 5530; OSH / OSL: Output upper / lower limits; specifically: OSH=VD0, OSL=VD4 for channel 1; OSH=VD12, OSL=VD16 for channel 2; Output: Engineering quantity output; Channel 1 output: VD500; Channel 2 output: VD504.

[0023] The conversion formula for S_ITR is a typical linear mapping, and will not be explained in detail here.

[0024] Furthermore, after obtaining the converted engineering quantity output, comparison is performed using FC_ALM to determine whether an alarm signal should be output. Specifically, this includes the following steps: Step S1: The differential pressure sensor and temperature sensor output 4–20mA analog signals, which are converted into raw digital signals by the PLC analog input module and stored in AIW16 and AIW18 respectively. Step S2: The PLC calls the analog quantity processing module FC_AI under the SM0.0 normally open enable, and maps AIW16 and AIW18 into engineering quantity outputs through the linear transformation module S_ITR. The output endpoints use the OSL / OSH parameters that can be configured by the human-machine interface 3, and output to VD500 and VD504 respectively. Step S3: The PLC calls the time processing module FT_TIME to generate the sampling cycle and alarm delay determination conditions; Step S4: The PLC calls the alarm module FC_ALM, compares VD500 and VD504 with the threshold, and outputs the alarm status in combination with the delay condition; Step S5: The human-machine interface 3 reads the engineering quantity and alarm status, displays and stores them, and outputs alarm information when the alarm is triggered.

[0025] Furthermore, such as Figure 2 As shown, the control system 1 of this application uses an external AC power supply as the power input. After passing through a short-circuit protector, the power supply enters the switching power supply module, which converts the 220V AC power into 24V DC power. The 24V DC power is used to power the control system 1, sensor components 2, and human-machine interface 3. The PLC main unit and the expansion I / O modules (…) Figure 2The right side of the middle section is the expansion module / terminal block, which is connected via the back panel or expansion bus; field sensor signals are connected to the PLC analog input terminal via terminal blocks (such as XT2 and XT3).

[0026] Furthermore, the control system 1 of this application can also acquire fan operation data collected by the fan operation sensor installed in the activated carbon box through the terminal block X1 at the input end. The fan operation signal is a switch status signal used to characterize whether the air supply system of the activated carbon box is in operation. When the fan operation signal X1 is valid, the control system 1 activates the monitoring and alarm logic: on the one hand, it performs engineering quantity conversion on the analog signals collected by the temperature and differential pressure sensors to generate operation data information; on the other hand, it outputs alarm information based on the comparison result of the operation data information and the preset threshold.

[0027] Preferably, when the fan operation signal is invalid, the control system 1 shall at least stop the alarm output and / or stop the operation data storage to avoid false alarms or invalid data recordings under shutdown conditions.

[0028] Preferably, the PLC control system 1 of this application uses a Siemens SR20 (12DI, 8DO), which is connected to the sensor and collects signals using a 0.75mm² RV cable. Simultaneously, the collected signals are converted from analog to digital by a program, and the corresponding data and alarm points are output to the human-machine interface 3. The differential pressure and temperature sensors are explosion-proof differential pressure transmitters (±10Kpa, 4-20mA) and explosion-proof temperature transmitters (PT100 to 4-20mA), respectively, and are installed using a plug-in method, mounted on the cover and end side of the activated carbon box, respectively, and connected to the analog input point of the PLC input terminal via a 0.75mm² flexible cable. The HMI human-machine interface 3 is fixed on the electrical cabinet door, communicates with the PLC control system 1 via RS485 communication, displays the data collected by the PLC control system 1, and outputs an alarm interface.

[0029] Furthermore, the human-computer interaction interface 3 also has data storage and export functions (see details). Figure 7 , Figure 9 Parameter setting function (see details) Figure 5 , Figure 6 Alarm logging function (see details) Figure 8 ) and activated carbon replacement record function (see details) Figure 10 ).

[0030] It is noteworthy that those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0031] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, as well as combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0032] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0033] These computer program instructions can also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0034] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention.

[0035] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0036] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A PLC control-based activated carbon tank monitoring system, characterized by, include: The control system (1), the sensor assembly (2) installed in the activated carbon box, and the human-machine interface (3) are as follows: The input terminal of the control system (1) is electrically connected to the sensor assembly (2), and the output terminal of the control system (1) is electrically connected to the human-machine interface (3). The input terminal is used to receive the sensor signal from the sensor assembly (2) set in the activated carbon box. The control system (1) processes the sensor signal to generate operating data information and transmits it to the human-machine interface (3) through the output terminal. The human-computer interaction interface (3) stores and displays the operation data information, and outputs alarm information based on the operation data information.

2. The activated carbon box monitoring system based on PLC control according to claim 1, characterized in that, The sensor assembly (2) includes at least one temperature sensor and at least one differential pressure sensor; The temperature sensor is used to detect the temperature inside the activated carbon box and outputs a temperature signal to the input terminal in the form of an analog signal. The differential pressure sensor is used to detect the pressure difference between the inlet and outlet of the activated carbon box and outputs a differential pressure signal to the input terminal in the form of an analog signal.

3. The activated carbon box monitoring system based on PLC control according to claim 2, characterized in that, The control system (1) is a PLC control system. The control system (1) performs engineering quantity conversion and logic processing on the temperature signal and the differential pressure signal respectively to generate temperature operation data information and differential pressure operation data information. The temperature operation data and the differential pressure operation data are transmitted to the human-machine interface (3) through the output terminal.

4. The activated carbon box monitoring system based on PLC control according to claim 3, characterized in that, The control system (1) collects the temperature signal and converts the temperature signal from an analog signal to a temperature engineering signal, matches the temperature engineering signal with a temperature threshold, and outputs a temperature alarm signal on the human-machine interface (3) when the temperature engineering signal exceeds the temperature threshold. The temperature alarm signal is included in the temperature operation data information. The control system (1) acquires the differential pressure signal and converts the differential pressure signal from an analog signal to a differential pressure engineering signal. It matches the differential pressure engineering signal with the differential pressure threshold. When the differential pressure engineering signal exceeds the differential pressure threshold, it outputs a differential pressure alarm signal on the human-machine interface (3). The differential pressure alarm signal is included in the differential pressure operation data information.

5. The activated carbon box monitoring system based on PLC control according to claim 4, characterized in that, Both the temperature threshold and the differential pressure threshold are configurable parameters and are written to the control system (1) by the human-machine interface (3).

6. The activated carbon box monitoring system based on PLC control according to claim 1, characterized in that, The control system (1) uses an external AC power supply as the power input. After passing through a short-circuit protector, the power supply enters the switching power supply module. The switching power supply module converts 220V AC power into 24V DC power. The 24V DC power is used to power the control system (1), the sensor assembly (2), and the human-machine interface (3).

7. The activated carbon box monitoring system based on PLC control according to claim 1, characterized in that, The sensor assembly (2) is connected to the input terminal via a terminal block.

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