Mining explosion-proof and intrinsically safe multifunctional intelligent switch device and algorithm thereof

Abstract

This invention discloses a mine-use explosion-proof and intrinsically safe multifunctional intelligent switchgear and its algorithm, belonging to the technical field of underground power supply control equipment in coal mines. The device includes an explosion-proof metal casing, power input sections on the left and right sides of the casing, multiple low-voltage permanent magnet vacuum feeder branches and low-voltage vacuum starter branches electrically connected to the power input sections on the front side of the casing, a three-phase lighting branch electrically connected to the power input sections on the front side of the casing, a data central processing unit and a programmable logic controller for controlling the orderly operation of each branch on the front side of the casing, and a backup power supply section inside the casing. By integrating the traditionally distributed feeder, starter, and lighting modules into the casing, the overall footprint is reduced, the installation process is simplified, and the backup power supply ensures that critical data is not lost and emergency control functions remain available during power outages.

Description

Technical Field

[0001] This invention relates to the field of underground power supply control equipment technology in coal mines, specifically to a mine-use explosion-proof and intrinsically safe multifunctional intelligent switch device and its algorithm. Background Technology

[0002] The underground working environment in coal mines is characterized by three main features: high risk (the presence of explosive mixtures such as gas and coal dust), limited space (narrow roadways and dispersed chambers), and complex equipment management (multiple types of electrical equipment need to operate in coordination). Explosion-proof and intrinsically safe switches, as key terminal equipment in underground power supply systems, must simultaneously meet the following functions: power supply control, safety protection, power distribution, real-time acquisition of operational data, and intrinsic explosion-proof safety.

[0003] Existing explosion-proof and intrinsically safe switches generally have the following problems: Low integration and poor space utilization: Existing underground switchgear in coal mines generally adopts a single-function independent design. For example, functional modules such as power supply switches (responsible for main circuit power supply), starters (control motor start and stop), lighting switches (dedicated lighting power supply), PLC control boxes (logic control), and data acquisition modules (monitoring and uploading) are all distributed and independent boxes. Each module needs to be installed in different chambers or roadways, resulting in a large overall footprint. Moreover, construction requires multiple excavations of chambers and laying of independent cables, which is difficult to install and has high maintenance costs. The distributed layout also increases the length of wiring between equipment, which not only wastes cable resources but also increases the difficulty of troubleshooting.

[0004] The cable distribution is messy, posing significant safety hazards: the power lines, control lines, and communication lines of the multiple branches of traditional switchgear are mixed and tangled, making them difficult to distinguish. This not only makes daily inspections inconvenient but also increases the risk of misoperation (such as accidentally touching live cables). Troubleshooting requires disassembling a large number of cables, which is time-consuming, labor-intensive, and may damage the original wiring structure. Summary of the Invention

[0005] The first technical problem to be solved by this invention is to provide a mining explosion-proof and intrinsically safe multifunctional intelligent switchgear and its algorithm. Through modular design and intelligent management, it improves the reliability, maintainability and space utilization of the underground power supply system, and solves the problems of low integration and poor space utilization of existing switchgear.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A mining explosion-proof and intrinsically safe multifunctional intelligent switch device includes an explosion-proof metal shell. Its core improvement lies in the following: power input sections are provided on the left and right ends of the explosion-proof metal shell; multiple low-voltage permanent magnet vacuum feeder branches and low-voltage vacuum starter branches are provided on the front of the explosion-proof metal shell and electrically connected to the power input sections; a three-phase lighting branch is also provided on the front of the explosion-proof metal shell and electrically connected to the power input sections; a data centralized processing unit and a programmable logic controller are also provided on the front of the explosion-proof metal shell to control the orderly operation of each branch; and a backup power supply section is provided inside the explosion-proof metal shell.

[0007] By adopting the above solution, the traditionally dispersed power supply, starter, lighting, control and power supply modules are integrated into a single housing through the integrated "multi-branch + intelligent control + backup power supply". This reduces the overall footprint, simplifies the installation process, and ensures that critical data is not lost and emergency control functions remain available during power outages through backup power supply.

[0008] As a preferred implementation method for a multi-functional intelligent switchgear that is both explosion-proof and intrinsically safe for mining applications, the explosion-proof metal casing contains multiple explosion-proof compartments. The power supply section is located within the power supply explosion-proof chamber, and all wiring harnesses from the power supply section are located within the wiring harness explosion-proof chamber between the power supply explosion-proof chambers. Each low-voltage permanent magnet vacuum feeder branch is located within a separate feeder branch explosion-proof chamber. Multiple low-voltage vacuum starter branches and the programmable logic controller are located together within the starter branch explosion-proof chamber. The three-phase lighting branch is located within the lighting explosion-proof chamber. The data central processing unit and the backup power supply are both located within the backup power explosion-proof chamber. This physical isolation separates different functional modules (such as high-voltage power supply and low-voltage control) into independent chambers, preventing the propagation of electric arcs / sparks across chambers and strictly meeting explosion-proof and intrinsically safe standards. Even if a chamber malfunctions (such as a short circuit in a feeder branch), it will not ignite explosive gases in other chambers, significantly improving overall explosion-proof safety.

[0009] As a preferred implementation of a mining-use explosion-proof and intrinsically safe multifunctional intelligent switchgear, the power supply section is used to connect to the explosion-proof terminal block. The power supply section includes a cable inlet pipe and a positioning flange connected to the end of the cable inlet pipe. A clearance groove, not exceeding half the length of the pipe body, is provided on the side of the cable inlet pipe. A fastening bracket extending into the cable inlet pipe is installed in the clearance groove. The fastening bracket can eccentrically fix the cable inside the cable inlet pipe. The fastening bracket fixes the cable (such as a high-voltage main cable) to the inner wall of the pipe, preventing the cables from sliding against each other and causing friction damage. At the same time, the clearance groove design facilitates the adjustment of the cable position during installation. Together with the positioning flange, it ensures the mechanical stability and explosion-proof sealing when the external cable is introduced.

[0010] As a preferred implementation method for a mine-use explosion-proof and intrinsically safe multifunctional intelligent switchgear, the wire harness explosion-proof chamber serves as the connection unit for each branch. After the power supply is introduced into the explosion-proof terminal block, the power supply is distributed to each branch through the wire harness explosion-proof chamber, and the output of each branch is distributed to its respective terminal block.

[0011] As a preferred implementation method for a mine-use explosion-proof and intrinsically safe multi-functional intelligent switchgear, the low-voltage permanent magnet vacuum feeder branch is used to supply power to low-voltage electrical equipment in the mine. Each feeder branch's explosion-proof chamber mainly includes a permanent magnet mechanism low-voltage vacuum circuit breaker, an electric bottom-discharge trolley, a bottom-discharge trolley controller, an intelligent integrated feeder protector with a display screen, a wireless temperature acquisition module, a video camera, an intelligent dehumidifier, and a small network switch. Each low-voltage permanent magnet vacuum feeder branch has its own independent LCD display, high-voltage live indicator, parameter setting buttons, power-off, power-on, manual-on, and leak-test buttons, a front door locking handle, and an observation window. The permanent magnet mechanism low-voltage vacuum circuit breaker is installed on the bottom-discharge trolley. A button sends a signal to the bottom-discharge trolley controller, which then controls the trolley's forward and backward movement. The bottom-discharge trolley then drives the permanent magnet mechanism low-voltage vacuum circuit breaker forward and backward. The circuit breaker is equipped with an electric chassis trolley, which uses a motor or manual drive screw to switch the circuit breaker between the working position and the maintenance and test position. When the electric trolley's drive motor is obstructed (due to improper installation or mechanism jamming) and the protection condition is met, the motor is immediately braked and driven in reverse to release the jammed state. The intelligent integrated power supply protector with a display screen provides real-time monitoring and overload, short circuit, leakage, over / under voltage protection for the incoming lines of the vacuum circuit breakers in each branch, and displays the operating status and parameters of each branch on the screen. High-definition industrial-grade miniature cameras are installed in the power distribution circuit compartment to monitor the position of the moving contacts and grounding switches of each circuit breaker. The video signals can be uploaded to the ground control center via the underground network, enabling remote operation visualization. The cameras are connected to the industrial switch in the central control compartment to transmit video signals via the network. The wireless temperature sensors are installed at the main circuit terminals of each power distribution circuit in the power distribution unit. Each circuit has six temperature sensors, which monitor the temperature of key points online in real time, generate temperature curves, and display the temperature data locally on the display screen in the feeder branch compartment. They can also be monitored remotely, transmitting temperature data to relevant equipment in the centralized control compartment via a wireless communication module. The bottom exhaust vehicle controller, intelligent integrated feeder protector with display screen, wireless temperature acquisition module, video camera, and intelligent dehumidifier are connected to a small network switch via network cables, and then the data is transmitted to the main industrial switch in the data centralized processing unit via explosion-proof network cables.

[0012] As a preferred implementation method for a mine-use explosion-proof and intrinsically safe multi-functional intelligent switchgear, the low-voltage vacuum starter branch is used to control the motors of equipment such as ventilators, water pumps, and conveyors. The low-voltage vacuum starter branch mainly includes a vacuum AC contactor, an intelligent integrated motor protector, a programmable logic controller (PLC), relays, a small network switch, and a color display screen. Power is connected to the isolating switch GS1 via cables and then distributed to the vacuum AC contactors of each starter branch. Each intelligent integrated motor protector provides protection and control for the vacuum AC contactors of its respective branch. The intelligent integrated motor protectors of each branch interact with the PLC via CAN communication technology, and the PLC provides overall control of the vacuum AC contactors of each branch. The PLC receives external signals, such as signals from a drainage pump, through its built-in analog and digital modules, and automatically controls the drainage pump through its built-in program. The PLC is connected to the main display screen of this section via a network cable, and the main display screen shows the operating status and parameters of each starter branch. The PLC is connected to a small network switch in this section via a network cable, and then the data is transmitted to the main industrial network switch via an explosion-proof network cable.

[0013] As a preferred implementation of a mine-use explosion-proof and intrinsically safe multi-functional intelligent switchgear, the three-phase lighting branch is used for lighting. This branch includes a 10KVA three-phase 127V lighting transformer, an intelligent integrated lighting protection device with a display screen, a vacuum AC contactor, and a small network switch. Power is introduced to the disconnector GS2 via a cable, then GS2 connects the power to the 10KVA three-phase 127V lighting transformer, and then transmits the 127V power out through the vacuum AC contactor. The intelligent integrated lighting protection device with a display screen controls, monitors, and protects this section of the line in real time, and is connected to the small network switch in this section via a network cable. Data is then transmitted to the main industrial switch via an explosion-proof network cable.

[0014] As a preferred implementation of a mine-use explosion-proof and intrinsically safe multifunctional intelligent switchgear, the data centralized processing unit serves as the overall data processing hub, comprising a large industrial switch, an Ethernet signal isolation and conversion module, and explosion-proof network cable wall-penetrating terminals. The main industrial switch reads data from the smaller switches on each branch line via the explosion-proof network cable wall-penetrating terminals, centrally processes various incoming data, and then connects to the Ethernet signal isolation and conversion module. This module converts the intrinsically safe network signals into intrinsically safe network signals, which are then transmitted to the host computer or ground control center via the explosion-proof network cable wall-penetrating terminals, enabling remote control of the invention by the host computer or ground control center. It realizes functions such as power distribution control, voltage, current, and temperature signal acquisition, network communication, operation display, and power supply control. The display screen and intrinsically safe keyboard allow for human-machine interaction, and the industrial switch enables underground network communication, uploading data to the ground control center or communicating with other underground equipment.

[0015] As a preferred implementation of a mining explosion-proof and intrinsically safe multifunctional intelligent switchgear, the backup power supply section includes a backup uninterruptible power supply and explosion-proof terminals; the backup power supply section enables data monitoring and transmission to continue for a period of time after the upstream power supply of this invention is interrupted.

[0016] An algorithm for a mine-use explosion-proof and intrinsically safe multi-functional intelligent switch is disclosed. The algorithm is stored in the programmable logic controller of the aforementioned mine-use explosion-proof and intrinsically safe multi-functional intelligent switch device. The algorithm has overcurrent protection, short-circuit protection, grounding protection, voltage protection, phase balance, wind power interlocking, system password, and fault recording functions.

[0017] I. Regarding overcurrent protection function; This device implements inverse-time overcurrent protection in response to current changes during operation. In the event of intermittent overload, it calculates the release and accumulation of overload energy based on the ratio of the overload current to the rated operating current and the duration of the overload, and then performs inverse-time protection. In high-voltage combined vacuum power distribution units, since the resistance of the unit can be considered constant under normal operating conditions, only the relationship between current and time needs to be considered. Specifically, the following two methods can be used.

[0018] Method 1: S1. Given that the rated current is Ie and the overload current is I0, calculate the overload factor k using the following formula: ; S2. Calculate the overload energy accumulation value Ea, the formula is: Where n is the number of samplings, ki is the overload factor of the i-th sampling, and Δt is the sampling interval; when the overload disappears, the energy release is calculated; when the overload disappears, the energy release is calculated. S3. First, set the energy release coefficient α, and calculate the released energy Er. The formula is as follows: , where t is the duration after the overload disappears; α can be determined through experiments in engineering practice; During intermittent overload, the accumulated and released energy is calculated using the above method. When the sum E accumulates to a preset threshold, the inverse time protection action is triggered. The protection action time E is the sum of the accumulated and released energy exceeding the preset threshold, and the accumulated and released energy is a preset constant.

[0019] Method 2: S1. Set up a digital integrator filter. The inputs to the filter are the overload factor and the time interval. Calculate the output of the filter as the overload energy accumulation value Ea, using the following formula: , where n is the sampling time, Ea(n) is the overload energy accumulation value at the nth time, Ea(n-1) is the overload energy accumulation value at the previous time, k(n) is the overload multiple at the nth time, and Δt is the time interval between two adjacent sampling times; S2. When the overload disappears, the released energy Ea is calculated again, and the formula is: , where β is the preset attenuation coefficient; it can also be determined through experiments in engineering practice; When Ea exceeds the set threshold, an inverse time protection action is triggered. The duration of the action is also inversely proportional, and the formula is as follows: Where C is a constant, this method effectively filters out the influence of short-term interference and noise on overload energy calculation, improving the accuracy of protection.

[0020] II. Regarding short-circuit protection function; The operating current of the short-circuit protection can be set arbitrarily within 1.5-10 times the rated current value, with an error of no more than ±10%, and the operating time of the short-circuit protection should be less than 0.1s.

[0021] III. Regarding the grounding (leakage) protection function; 1) Zero-sequence power directional grounding (leakage) protection, with the following characteristics: primary zero-sequence current range (A): 0.5, 1.0, 2.0, 4.0, 6.0; secondary zero-sequence voltage range (V): 3.0, 5.0, 10, 20, 25; operating time range (s): <0.1, <0.5, <1.0, <1.5; error value ≤±10%; operating range <180°; 2) Zero-sequence current type grounding (leakage) protection, its characteristics are as follows: the primary zero-sequence current range (A) of the zero-sequence current type grounding (leakage) protection is 0.5, 1.0, 2.0, 4.0, 6.0; the action time is 0.1s, and the error value is less than ±10%; IV. Voltage protection function; include: 1) Undervoltage protection: Reliable protection when the mains voltage drops below 75% of the rated value; the undervoltage protection action time is ≤5 seconds. 2) Overvoltage protection: Reliable protection is provided when the mains voltage rises to more than 115% of the rated value; the overvoltage protection will activate. Time ≤ 5 seconds; The operating values ​​for undervoltage and overvoltage protection can also be preset as specified.

[0022] V. Phase balance function; If any phase power supply is interrupted and the current is lower or higher than the load current of the other two phases by 50%, the protection will activate after a delay of 5 to 30 seconds. The phase balance function has an on / off menu, allowing users to freely choose to turn it on or off.

[0023] VI. Wind power interlock function; When used in conjunction with a gas power cut-off device, the device will output an alert and display a gas over-limit warning.

[0024] VII. System password function; To prevent unauthorized operation, the password function can be set to be turned on or off.

[0025] 8. Fault recording function; The system uses an internationally standard waveform recording file format to store fault waveform data for the 37 cycles before and 20 cycles after the fault, which can be queried at any time to facilitate the analysis of the cause of the fault. Multiple fault waveform recording start modes are available, which not only facilitate the investigation and analysis of the cause of the fault after the accident, but also guide users in setting the settings. The system also adds a switch closing waveform recording function, which can analyze the changes in voltage and current signals at the moment the switch is closed.

[0026] The second technical problem to be solved by the present invention is to provide a multi-functional intelligent switch device for mining that is both explosion-proof and intrinsically safe. By setting up a centralized cable bundling device in multiple explosion-proof compartments, the device enables single-strand cable routing and classified management, thus solving the problem of messy cable distribution and prominent safety hazards in existing switch devices.

[0027] To achieve the above objectives, the present invention provides the following technical solution: Based on the above scheme, a cable tray is provided between the explosion-proof chamber of the wire harness and each branch for threading cables. Each cable tray is equipped with a centralized cable tray device for threading all cables one by one at intervals. The centralized cable tray device consists of a cable tray frame, a cable tray reel, and a cable tray ring. The cable tray reel is coaxially installed on the inner side of the cable tray frame, and the cable tray ring is coaxially installed on the front side of the cable tray reel.

[0028] By adopting the above solution, the cables of each branch (power line, control line, communication line) are threaded through the cable bundle device at individual intervals (to avoid tangling), and centralized management facilitates quick location of target cables during later maintenance.

[0029] As a preferred implementation of a mine-use explosion-proof and intrinsically safe multifunctional intelligent switch device, the cable tray includes multiple cable tray grooves opened radially therefrom, each cable tray groove extending to the edge of the cable tray; the cable tray grooves are divided into long cable tray grooves, medium cable tray grooves and short cable tray grooves, which are arranged sequentially around the circumference of the cable tray; according to the cable length (e.g., long power line → long cable tray groove, short control line → short cable tray groove), the cables are classified and inserted into the corresponding grooves to avoid cross-extrusion and ensure that each cable is independently fixed, further improving the standardization of wiring.

[0030] As a preferred implementation of a mining explosion-proof and intrinsically safe multifunctional intelligent switch device, multiple slots are provided on the inner side of the cable tray frame, and multiple clips that cooperate with the slots are connected to the edge of the cable tray. The cable tray and the cable tray frame are fixed together by the slots and clips. The modular design supports quick disassembly and assembly of the cable tray (without tools), which makes it easy to remove the cable tray separately to check the internal cables during maintenance. At the same time, the clip structure ensures a firm fixation (shockproof and anti-loosening).

[0031] As a preferred implementation method for a mining-use explosion-proof and intrinsically safe multifunctional intelligent switchgear, the cable tie ring is divided into a large cable tie ring, a medium cable tie ring, and a small cable tie ring. The large, medium, and small cable tie rings are used in conjunction with the long, medium, and short cable tie slots, respectively. A pin is connected to the edge of the cable tie ring, and three insertion holes, all of which can be used with the pin, are provided on the cable tie plate. The cable tie plate and the cable tie ring are fixed by the pin and the insertion holes. The cable tie ring of the corresponding size is selected according to the type of cable tie slot to further prevent the cable from loosening and ensure the stability of the wiring.

[0032] The beneficial effects of this invention are: 1. High integration: The functions of power supply, starter, lighting, control, power supply, and monitoring are integrated into a single explosion-proof enclosure, which reduces the number of downhole equipment, saves space, and reduces the difficulty of installation and maintenance; 2. Intelligent protection and monitoring: Multiple branches are equipped with leakage / overload / short circuit / wireless temperature measurement and other protections, supporting remote leakage test and video monitoring. The fault response time is <0.1 seconds and the false trip rate is <0.01%, which greatly improves the safety of power supply. 3. Standardized cabling: By installing centralized cable management devices (cable trays / rings with graded matching) in multiple explosion-proof compartments, individual cable routing and classified management are achieved, reducing cable positioning time by 60% during maintenance; 4. Intrinsically safe explosion-proof design: Multi-chamber explosion-proof design and mechanical protection such as fasteners / cable rings prevent electric sparks from igniting explosive gases, suitable for Zone 0 / Zone 1 hazardous environments; 5. Flexible expansion: The programmable logic controller supports custom control logic, and the main display screen human-machine interface supports remote parameter modification to adapt to the changing production needs of different coal mines. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art 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.

[0034] Figure 1 This is a three-dimensional structural diagram of the mine explosion-proof and intrinsically safe multi-functional intelligent switch device in Example 1 from a first angle. Figure 2 This is a three-dimensional structural diagram of the mine explosion-proof and intrinsically safe multi-functional intelligent switch device in Example 1 from a second angle. Figure 3 This is a three-dimensional structural diagram of the mine explosion-proof and intrinsically safe multi-functional intelligent switch device in Example 1 from a third angle. Figure 4 The internal three-dimensional structure of the mine-use explosion-proof and intrinsically safe multi-functional intelligent switch device in Example 1. Figure 1 ; Figure 5 The internal three-dimensional structure of the mine-use explosion-proof and intrinsically safe multi-functional intelligent switch device in Example 1. Figure 2 ; Figure 6 A three-dimensional structural diagram of the power supply section from a first angle; Figure 7 A three-dimensional structural diagram of the power supply section from a second angle; Figure 8 A schematic diagram of the power supply system for each branch; Figure 9 The human-computer interaction interface for the main display screen; Figure 10 This is a three-dimensional structural diagram of the mine explosion-proof and intrinsically safe multi-functional intelligent switch device (hidden rear inspection plate) in Example 2; Figure 11 This is a three-dimensional structural diagram of the mining explosion-proof and intrinsically safe multifunctional intelligent switch device in Example 2; Figure 12 This is a three-dimensional structural diagram of the centralized wire bundle device in application. Figure 13 This is a three-dimensional structural diagram of the centralized wire-bundling device; Figure 14 This is a three-dimensional structural diagram of the wire harness frame; Figure 15 This is a three-dimensional structural diagram of the cable tie. Figure 16 This is a three-dimensional structural diagram of the wire loop.

[0035] In the diagram, the markings are: 1-Explosion-proof metal casing; 2-Power supply section; 21-Including cable inlet pipe; 22-Positioning flange; 23-Clearing groove; 24-Fixing bracket; 3-Low-voltage permanent magnet vacuum feeder branch; 4-Low-voltage vacuum starter branch; 5-Three-phase lighting branch; 6-Data central processing unit; 7-Programmable logic controller; 8-Backup power supply section; 9-Power supply explosion-proof chamber; 10-Wire harness explosion-proof chamber; 11-Feeder branch explosion-proof chamber. 12-Starter branch explosion-proof chamber; 13-Lighting explosion-proof chamber; 14-Backup power explosion-proof chamber; 15-Centralized cable bundle device; 151-Cable bundle frame; 152-Cable bundle reel; 153A-Long cable bundle ring; 153B-Medium cable bundle ring; 153C-Short cable bundle ring; 154A-Long cable bundle groove; 154B-Medium cable bundle groove; 154C-Short cable bundle groove; 155-Card slot; 156-Card head; 157-Pin; 158-Socket. Detailed Implementation

[0036] 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.

[0037] Example 1, as Figures 1 to 3As shown, a multi-functional intelligent switchgear for mining, combining explosion-proof and intrinsically safe features, is provided. It is used in combination switches or main drainage pump room power distribution control for underground coal mine faces, fully mechanized coal mine faces, conveyor belt heads and tails, and pump stations. Specifically, it includes an explosion-proof metal housing. Power input sections are located on the left and right sides of the housing. Multiple low-voltage permanent magnet vacuum feeder branches and low-voltage vacuum starter branches, electrically connected to the power input sections, are located on the front of the housing. A three-phase lighting branch, also electrically connected to the power input sections, is also located on the front of the housing. A data processing unit and a programmable logic controller (PLC) for controlling the orderly operation of each branch are also located on the front of the housing. A backup power supply is located inside the housing. Through the integrated design of "multiple branches + intelligent control + backup power supply," the traditionally dispersed feeder, starter, lighting, control, and power supply modules are integrated into a single housing, reducing the overall footprint, simplifying the installation process, and ensuring that critical data is not lost and emergency control functions remain available during power outages through the backup power supply.

[0038] like Figures 4 to 5 As shown, the explosion-proof metal enclosure contains multiple explosion-proof compartments. The power supply section is located within the explosion-proof power supply compartment and is used to connect to explosion-proof terminals. All wiring harnesses from the power supply section are located within the explosion-proof wiring harness compartments between the power supply compartments, serving as connecting units for various branches. Each low-voltage permanent magnet vacuum feeder branch is located within a separate explosion-proof feeder branch compartment, supplying power to various low-voltage electrical equipment in the mine. Multiple low-voltage vacuum starter branches and a programmable logic controller (PLC) are located within the explosion-proof starter branch compartment. The low-voltage vacuum starter branches control the motors of equipment such as fans, pumps, and conveyors. The three-phase lighting branch is located in the explosion-proof lighting chamber and is used for lighting. The data central processing unit and the backup power supply are both located in the explosion-proof backup power supply chamber. The data central processing unit is the hub for data central processing, and the backup power supply can record the state before the power failure and transmit the information to the host computer or ground control center after the power failure. The above physical isolation separates different functional modules (such as high-voltage power supply and low-voltage control) into independent chambers to prevent the propagation of electric arcs / sparks across chambers, strictly meeting the explosion-proof and intrinsic safety standards. Even if a fault occurs in a chamber (such as a short circuit in the power supply branch), it will not ignite the explosive gas in other chambers, greatly improving the overall explosion-proof safety.

[0039] like Figures 6 to 7As shown, the power supply section is used to connect to the explosion-proof terminal block. The power supply section includes a cable inlet pipe and a positioning flange connected to the end of the cable inlet pipe. A clearance groove, not exceeding half the length of the pipe body, is provided on the side of the cable inlet pipe. A fastening bracket extending into the cable inlet pipe is installed in the clearance groove. The fastening bracket can eccentrically fix the cable inside the cable inlet pipe. The fastening bracket fixes the cable (such as a high-voltage main cable) to the inner wall of the pipe, preventing the cables from sliding against each other and causing friction damage. At the same time, the clearance groove design facilitates the adjustment of the cable position during installation. Together with the positioning flange, it ensures the mechanical stability and explosion-proof sealing when the external cable is introduced.

[0040] like Figures 4 to 5 , Figure 8 As shown, the explosion-proof chamber of the wiring harness serves as the connection unit for each branch. After the power supply is introduced into the explosion-proof terminal block, it is distributed to each branch through the explosion-proof chamber of the wiring harness, and the output of each branch is distributed to its respective wiring chamber.

[0041] like Figures 4 to 5As shown, the low-voltage permanent magnet vacuum feeder branch is used to supply power to low-voltage electrical equipment in the mine. Each feeder branch's explosion-proof chamber mainly includes a permanent magnet mechanism low-voltage vacuum circuit breaker, an electric bottom-exhaust trolley, a bottom-exhaust trolley controller, an intelligent integrated feeder protector with a display screen, a wireless temperature acquisition module, a video camera, an intelligent dehumidifier, and a small network switch. Each low-voltage permanent magnet vacuum feeder branch has its own independent LCD display, high-voltage live indicator, parameter setting buttons, power-off, power-on, manual-on, and leak-test buttons, a front door locking handle, and an observation window. The permanent magnet mechanism low-voltage vacuum circuit breaker is installed on the bottom-exhaust trolley. A button sends a signal to the bottom-exhaust trolley controller, which then controls the trolley's forward and backward movement. The bottom-exhaust trolley then drives the permanent magnet mechanism low-voltage vacuum circuit breaker forward and backward. The circuit breaker is equipped with an electric chassis trolley, which uses a motor or manual drive screw to switch the circuit breaker between the working position and the maintenance and test position. When the electric trolley's drive motor is obstructed (due to improper installation or mechanism jamming) and the protection condition is met, the motor is immediately braked and driven in reverse to release the jammed state. The intelligent integrated power supply protector with a display screen provides real-time monitoring and overload, short circuit, leakage, over / under voltage protection for the incoming lines of the vacuum circuit breakers in each branch, and displays the operating status and parameters of each branch on the screen. High-definition industrial-grade miniature cameras are installed in the power distribution circuit compartment to monitor the position of the moving contacts and grounding switches of each circuit breaker. The video signals can be uploaded to the ground control center via the underground network, enabling remote operation visualization. The cameras are connected to the industrial switch in the central control compartment to transmit video signals via the network. The wireless temperature sensors are installed at the main circuit terminals of each power distribution circuit in the power distribution unit. Each circuit has six temperature sensors, which monitor the temperature of key points online in real time, generate temperature curves, and display the temperature data locally on the display screen in the feeder branch compartment. They can also be monitored remotely, transmitting temperature data to relevant equipment in the centralized control compartment via a wireless communication module. The bottom exhaust vehicle controller, intelligent integrated feeder protector with display screen, wireless temperature acquisition module, video camera, and intelligent dehumidifier are connected to a small network switch via network cables, and then the data is transmitted to the main industrial switch in the data centralized processing unit via explosion-proof network cables.

[0042] like Figures 4 to 5 , Figure 9 As shown, the low-voltage vacuum starter branch is used to control the motors of equipment such as fans, pumps, and conveyors. The low-voltage vacuum starter branch mainly includes a vacuum AC contactor, an intelligent integrated motor protector, a programmable logic controller (PLC), relays, a small network switch, and a color display screen. Power is connected to the isolating switch GS1 via cables and then distributed to the vacuum AC contactors (such as...) of each starter branch. Figure 8(The area circled in dashed box 2) Each intelligent integrated motor protector provides protection and control for the vacuum AC contactors of each branch. Each branch's intelligent integrated motor protector interacts with the programmable logic controller (PLC) via CAN communication technology. The PLC provides overall control of the vacuum AC contactors in each branch. The PLC receives external signals, such as signals from the drainage pump, through its built-in analog and digital modules, and automatically controls the drainage pump using its built-in program. The PLC is connected to the main display screen of this section via a network cable, which displays the operating status and parameters of each starter branch. The PLC is also connected to a small network switch in this section via a network cable, and then transmits data to the main industrial network switch via an explosion-proof network cable.

[0043] Continue as Figures 4 to 5 As shown, the three-phase lighting branch is used for lighting; the three-phase lighting branch includes a 10KVA three-phase 127V lighting transformer, an intelligent integrated lighting protection device with a display screen, a vacuum AC contactor, and a small network switch. Power is introduced to the disconnecting switch GS2 via a cable, then GS2 connects the power to the 10KVA three-phase 127V lighting transformer, and then the 127V is transmitted out through the vacuum AC contactor (e.g., ...). Figure 8 (The area circled in dashed box 3). The intelligent integrated lighting protection device with display screen controls and monitors the incoming line of this section in real time and provides protection. It is connected to a small network switch in this section via a network cable, and then transmits the data to the main industrial switch via an explosion-proof network cable.

[0044] Continue as Figures 4 to 5 As shown, the centralized data processing unit is the overall data processing hub, including a large industrial switch, an Ethernet signal isolation and conversion module, and explosion-proof network cable wall-penetrating terminals. The main industrial switch reads data from the smaller switches on each branch line through the explosion-proof network cable wall-penetrating terminals, centrally processes various incoming data, and then connects to the Ethernet signal isolation and conversion module. This module converts the intrinsically safe network signals into intrinsically safe network signals, and the explosion-proof network cable wall-penetrating terminals then transmit the data to the host computer or ground control center, enabling remote control of the invention by the host computer or ground control center. It realizes functions such as power distribution control, voltage, current, and temperature signal acquisition, network communication, operation display, and power supply control. The display screen and intrinsically safe keyboard allow for human-machine interaction, and the industrial switch enables underground network communication, uploading data to the ground control center or communicating with other underground equipment.

[0045] Continue as Figures 4 to 5 As shown, the backup power supply section includes a backup uninterruptible power supply and explosion-proof terminals; the backup power supply section enables data monitoring and transmission to continue for a period of time after the upstream power supply of this invention is interrupted.

[0046] An algorithm for a mine-use explosion-proof and intrinsically safe multi-functional intelligent switch is disclosed. The algorithm is stored in the programmable logic controller of the aforementioned mine-use explosion-proof and intrinsically safe multi-functional intelligent switch device. The algorithm has overcurrent protection, short-circuit protection, grounding protection, voltage protection, phase balance, wind power interlocking, system password, and fault recording functions.

[0047] I. Regarding overcurrent protection function; This device implements inverse-time overcurrent protection in response to current changes during operation. In the event of intermittent overload, it calculates the release and accumulation of overload energy based on the ratio of the overload current to the rated operating current and the duration of the overload, and then performs inverse-time protection. In high-voltage combined vacuum power distribution units, since the resistance of the unit can be considered constant under normal operating conditions, only the relationship between current and time needs to be considered. Specifically, the following two methods can be used.

[0048] Method 1: S1. Given that the rated current is Ie and the overload current is I0, calculate the overload factor k using the following formula: ; S2. Calculate the overload energy accumulation value Ea, the formula is: Where n is the number of samplings, ki is the overload factor of the i-th sampling, and Δt is the sampling interval; when the overload disappears, the energy release is calculated; when the overload disappears, the energy release is calculated. S3. First, set the energy release coefficient α, and calculate the released energy Er. The formula is as follows: , where t is the duration after the overload disappears; α can be determined through experiments in engineering practice; During intermittent overload, the accumulated and released energy is calculated using the above method. When the sum E accumulates to a preset threshold, the inverse time protection action is triggered. The protection action time E is the sum of the accumulated and released energy exceeding the preset threshold, and the accumulated and released energy is a preset constant.

[0049] Method 2: S1. Set up a digital integrator filter. The inputs to the filter are the overload factor and the time interval. Calculate the output of the filter as the overload energy accumulation value Ea, using the following formula: , where n is the sampling time, Ea(n) is the overload energy accumulation value at the nth time, Ea(n-1) is the overload energy accumulation value at the previous time, k(n) is the overload multiple at the nth time, and Δt is the time interval between two adjacent sampling times; S2. When the overload disappears, the released energy Ea is calculated again, and the formula is: , where β is the preset attenuation coefficient; it can also be determined through experiments in engineering practice; When Ea exceeds the set threshold, an inverse time protection action is triggered. The duration of the action is also inversely proportional, and the formula is as follows: Where C is a constant, this method effectively filters out the influence of short-term interference and noise on overload energy calculation, improving the accuracy of protection.

[0050] II. Regarding short-circuit protection function; The operating current of the short-circuit protection can be set arbitrarily within 1.5-10 times the rated current value, with an error of no more than ±10%, and the operating time of the short-circuit protection should be less than 0.1s.

[0051] III. Regarding the grounding (leakage) protection function; 1) Zero-sequence power directional grounding (leakage) protection, with the following characteristics: primary zero-sequence current range (A): 0.5, 1.0, 2.0, 4.0, 6.0; secondary zero-sequence voltage range (V): 3.0, 5.0, 10, 20, 25; operating time range (s): <0.1, <0.5, <1.0, <1.5; error value ≤±10%; operating range <180°; 2) Zero-sequence current type grounding (leakage) protection, its characteristics are as follows: the primary zero-sequence current range (A) of the zero-sequence current type grounding (leakage) protection is 0.5, 1.0, 2.0, 4.0, 6.0; the action time is 0.1s, and the error value is less than ±10%; IV. Voltage protection function; include: 1) Undervoltage protection: Reliable protection when the mains voltage drops below 75% of the rated value; the undervoltage protection action time is ≤5 seconds. 2) Overvoltage protection: Reliable protection is provided when the mains voltage rises to more than 115% of the rated value; the overvoltage protection will activate. Time ≤ 5 seconds; The operating values ​​for undervoltage and overvoltage protection can also be preset as specified.

[0052] V. Phase balance function; If any phase power supply is interrupted and the current is lower or higher than the load current of the other two phases by 50%, the protection will activate after a delay of 5 to 30 seconds. The phase balance function has an on / off menu, allowing users to freely choose to turn it on or off.

[0053] VI. Wind power interlock function; When used in conjunction with a gas power cut-off device, the device will output an alert and display a gas over-limit warning.

[0054] VII. System password function; To prevent unauthorized operation, the password function can be set to be turned on or off.

[0055] 8. Fault recording function; The system uses an internationally standard waveform recording file format to store fault waveform data for the 37 cycles before and 20 cycles after the fault, which can be queried at any time to facilitate the analysis of the cause of the fault. Multiple fault waveform recording start modes are available, which not only facilitate the investigation and analysis of the cause of the fault after the accident, but also guide users in setting the settings. The system also adds a switch closing waveform recording function, which can analyze the changes in voltage and current signals at the moment the switch is closed.

[0056] Example 2, as Figures 10 to 13 As shown, a multi-functional intelligent switch device with explosion-proof and intrinsically safe features for mining is provided. It is applied to combined switches or main drainage pump room power distribution control in underground coal mine faces, fully mechanized coal mine faces, conveyor belt heads and tails, and pump stations. The explosion-proof chamber of the wiring harness is equipped with cable routing ports between the cable harness and each branch circuit. The difference between this embodiment and Embodiment 1 is that a centralized cable routing device is installed in each cable routing port to route all cables individually at intervals. The centralized cable routing device consists of a cable routing frame, a cable routing reel, and a cable routing ring. The cable routing reel is coaxially mounted inside the cable routing frame, and the cable routing ring is coaxially mounted in front of the cable routing reel. The cable routing device routes each branch circuit cable (power line, control line, communication line) individually at intervals (avoiding tangling), and centralized management facilitates quick location of target cables during later maintenance.

[0057] like Figures 14 to 16 As shown, the cable tray includes multiple cable tray slots opened radially thereon, each cable tray extending to the edge of the cable tray; the cable tray slots are divided into long cable tray slots, medium cable tray slots and short cable tray slots, which are arranged sequentially around the circumference of the cable tray; the cables are classified and inserted into the corresponding slots according to their length (e.g., long power cables → long cable tray, short control cables → short cable tray), avoiding cable crossing and compression, ensuring that each cable is independently fixed, and further improving the standardization of wiring.

[0058] Continue as Figures 14 to 16 As shown, multiple slots are provided on the inner side of the cable tray frame, and multiple clips that cooperate with the slots are connected to the edge of the cable tray. The cable tray and the cable tray frame are fixed together by the slots and clips. The modular design supports quick assembly and disassembly of the cable tray (without tools), making it easy to remove the cable tray separately to check the internal cables during maintenance. At the same time, the clip structure ensures a firm fixation (shockproof and anti-loosening).

[0059] Continue as Figures 14 to 16As shown, cable tie rings are divided into large, medium, and small cable tie rings. These rings are used in conjunction with long, medium, and short cable tie slots, respectively. A pin is connected to the edge of each cable tie ring, and three insertion holes, all of which can be used with the pin, are provided on the cable tie reel. The cable tie reel and cable tie ring are fixed together by the pin and the insertion holes. Selecting the appropriate size cable tie ring based on the type of cable tie slot further prevents cable loosening and ensures wiring stability.

[0060] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A mining explosion-proof and intrinsically safe multifunctional intelligent switch device, comprising an explosion-proof metal shell, characterized in that: The explosion-proof metal enclosure has power input sections on the left and right sides. On the front side of the explosion-proof metal enclosure, there are multiple low-voltage permanent magnet vacuum feeder branches and low-voltage vacuum starter branches that are electrically connected to the power input sections. On the front side of the explosion-proof metal enclosure, there is also a three-phase lighting branch that is electrically connected to the power input sections. On the front side of the explosion-proof metal enclosure, there is also a data central processing unit and a programmable logic controller that control the orderly operation of each branch. Inside the explosion-proof metal enclosure, there is a backup power supply section.

2. The mine flame-proof and intrinsically safe multifunctional intelligent switch device according to claim 1, characterized in that, The explosion-proof metal housing contains multiple explosion-proof compartments. The power supply section is located in the power supply explosion-proof chamber. All wiring harnesses from the power supply section are located in the wiring harness explosion-proof chamber between the power supply explosion-proof chambers. Each low-voltage permanent magnet vacuum feeder branch is located in a separate feeder branch explosion-proof chamber. Multiple low-voltage vacuum starter branches and the programmable logic controller are located together in the starter branch explosion-proof chamber. The three-phase lighting branch is located in the lighting explosion-proof chamber. The data centralized processing unit and the backup power supply are both located in the backup power explosion-proof chamber.

3. The mine flame-proof and intrinsically safe multifunctional intelligent switch device according to claim 1, characterized in that, The power supply section includes a cable inlet pipe and a positioning flange connected to the end of the cable inlet pipe. A clearance groove with a length not exceeding half of the pipe body is provided on the side of the cable inlet pipe. A fastening bracket extending into the cable inlet pipe is installed in the clearance groove. The fastening bracket can eccentrically fix the cable in the cable inlet pipe inside the pipe.

4. The mine flame-proof and intrinsically safe multifunctional intelligent switch device according to claim 2, characterized in that, The explosion-proof chamber of the wire harness is provided with a wire harness opening between the wire harness and each branch for threading the wires. Each wire harness opening is equipped with a centralized wire harnessing device for threading all the wires individually at intervals. The centralized wire harnessing device consists of a wire harness frame, a wire harness reel, and a wire harness ring. The wire harness reel is coaxially installed on the inner side of the wire harness frame, and the wire harness ring is coaxially installed on the front side of the wire harness reel.

5. The flame-proof and intrinsically safe multifunctional intelligent switchgear for mine as claimed in claim 4 wherein, The cable tray includes multiple cable tray grooves that are opened radially thereon, each cable tray groove extending to the edge of the cable tray; the cable tray grooves are divided into long cable tray grooves, medium cable tray grooves and short cable tray grooves, which are arranged sequentially along the circumference of the cable tray.

6. The mining explosion-proof and intrinsically safe multifunctional intelligent switch device according to claim 4, characterized in that, Multiple slots are provided on the inner side of the cable tie frame, and multiple clips that cooperate with the slots are connected to the edge of the cable tie plate. The cable tie plate and the cable tie frame are fixed together by the slots and clips.

7. The flame-proof and intrinsically safe multifunctional intelligent switchgear for mine as claimed in claim 4 wherein, The cable tie ring is divided into a large cable tie ring, a medium cable tie ring, and a small cable tie ring. The large cable tie ring, the medium cable tie ring, and the small cable tie ring are used in conjunction with the long cable tie groove, the medium cable tie groove, and the short cable tie groove, respectively. A pin is connected to the edge of the cable tie ring. Three insertion holes are provided on the cable tie plate, each of which can be used with the pin. The cable tie plate and the cable tie ring are fixed together by the pin and the insertion holes.

8. A mining explosion-proof and intrinsically safe multi-functional intelligent switch algorithm, wherein the algorithm is stored in the programmable logic controller of the mining explosion-proof and intrinsically safe multi-functional intelligent switch device according to claim 1, characterized in that: The algorithm has overcurrent protection, short circuit protection, grounding protection, voltage protection, phase balance, wind power interlocking, system password, and fault recording functions.

9. The algorithm of multifunctional intelligent switch for mine explosion-proof and intrinsically safe type according to claim 8, characterized in that, The overcurrent protection function adopts the following approach; S1, set the rated current is Ie, overload current is I0, calculate the overload factor k, the formula is: ; S2, calculate the overload energy accumulation value Ea, whose formula is: ; wherein n is the sampling number, ki is the overload multiple of the i-th sampling, and Δt is the sampling interval time; Calculate the energy release when the overload disappears; S3, first set the energy release coefficient α, calculate the energy Er after release, its formula is: Where t is the time after the disappearance of the overload; α can be determined by test in engineering practice; During intermittent overload, the accumulated and released energy is calculated using the above method. When the sum E accumulates to a preset threshold, the inverse time protection action is triggered. The protection action time E is the sum of the accumulated and released energy exceeding the preset threshold, and the accumulated and released energy is a preset constant.

10. The mining explosion-proof and intrinsically safe multifunctional intelligent switch algorithm according to claim 8, characterized in that, For overcurrent protection, the following methods can also be used; S1. Set up a digital integrator filter. The inputs to the filter are the overload factor and the time interval. Calculate the output of the filter as the overload energy accumulation value Ea, using the following formula: , where n is the sampling time, Ea(n) is the overload energy accumulation value at the nth time, Ea(n-1) is the overload energy accumulation value at the previous time, k(n) is the overload multiple at the nth time, and Δt is the time interval between two adjacent sampling times; S2. When the overload disappears, the released energy Ea is calculated again, and the formula is: , where β is the preset attenuation coefficient; it can also be determined through experiments in engineering practice; When Ea exceeds the set threshold, an inverse time protection action is triggered. The duration of the action is also inversely proportional, and the formula is as follows: Where C is a constant, this method effectively filters out the influence of short-term interference and noise on overload energy calculation, improving the accuracy of protection.

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