Intelligent emergency control system for a linkage device

Abstract

The application belongs to the technical field of electrical control, and specifically relates to an intelligent emergency control system of linkage equipment, which can monitor communication and heartbeat of a main control system in real time, collect stable cycle average frequency and current before failure and generate a failure snapshot when the main control fails, assess working condition risks by calculating a safe continuation coefficient, distinguish output automatic continuation or manual standby instructions, quickly complete control right switching through seamless switching modules, output matching frequency signals in an automatic mode to maintain smooth operation of the equipment, open local operation authority in a manual mode, verify current change rate after switching is completed, and perform emergency shutdown and sound-light alarm when current impact exceeds a standard, thereby greatly reducing unplanned shutdown and avoiding production line interruption, adapting different working conditions through a hierarchical emergency strategy, effectively avoiding secondary accidents such as overload and impact through a double safety verification mechanism, and being compatible with conventional main control and frequency converter equipment.

Description

Technical Field

[0001] This invention relates to the field of electrical control technology, specifically to an intelligent emergency control system for interconnected equipment. Background Technology

[0002] In modern process industries, human-machine interfaces, programmable logic controllers, distributed control systems, and frequency converter integrated control systems have been widely used in many fields such as coke smelting, chemical production, mining, and power energy. As a key execution unit, the frequency converter receives control commands from the human-machine interface and PLC / DCS according to the production process requirements, and drives the operation of various pumps, fans, compressors and other linked equipment to form a complete production chain.

[0003] Currently, the architecture of control systems is generally as follows: operators issue control commands through a human-machine interface, and the PLC / DCS receives the commands, processes them, and outputs analog or digital signals to control the start, stop, and speed regulation of the frequency converter. However, this architecture still has the following significant safety hazards:

[0004] When the human-machine interface, PLC / DCS malfunctions due to power failure, communication link disconnection, CPU crash, or damage to I / O module components, the control system will completely lose its ability to control the frequency converter. The frequency converter will then stop outputting, causing the driven linked equipment to stop operating out of control. For continuous production process industries, unplanned shutdown of a single critical piece of equipment can cause a chain reaction in upstream and downstream sections in a very short time, leading to partial or even complete production stoppages. At the same time, it is accompanied by abnormal leakage or spillage of toxic and harmful substances, resulting in huge economic losses and safety and environmental risks.

[0005] Therefore, developing an emergency control system for linkage equipment that can comprehensively cover various control system failure scenarios and enable rapid and smooth emergency start-up and operation of linkage equipment has become an urgent technical problem to be solved in the field of electrical control. Summary of the Invention

[0006] The purpose of this invention is to provide an intelligent emergency control system for interconnected equipment to solve the above-mentioned technical problems.

[0007] To achieve the above objectives, the present invention provides the following technical solution: an intelligent emergency control system for linked equipment, comprising an operational situation awareness module, an emergency strategy generation module, and a seamless switching execution module;

[0008] The operational situation awareness module monitors the health status of the main control system in a comprehensive and high-frequency manner, and outputs fault snapshot data packets to the emergency strategy generation module;

[0009] The emergency strategy generation module analyzes and generates strategies based on fault snapshot data packets, and outputs automatic continuation instructions or manual standby instructions to the seamless switching execution module.

[0010] Seamlessly switch execution modules to automatically execute emergency commands issued by the emergency strategy generation module.

[0011] Furthermore, the operation process of the situational awareness module includes:

[0012] When the heartbeat signal of the main control system is lost or communication timeout is detected, the current time t0 is immediately locked, and the average output frequency Favg and average output current Iavg in the previous stable operating cycle before time t0 are recorded, and these parameters are encapsulated into a fault snapshot data packet.

[0013] Furthermore, the average output current Iavg and the average output frequency Favg are calculated in the same way, and the average output frequency Favg is calculated as follows: Favg=(ΣFout(i)) / N; where Fout(i) is the output frequency of the i-th sampling point in the previous stable period before time t0, and N is the total number of sampling points in the previous stable period before time t0.

[0014] Furthermore, the specific process of the emergency strategy generation module analyzing and generating strategies based on fault snapshot data packets is as follows:

[0015] The system receives fault snapshot data packets, parses out the average output frequency Favg and average output current Iavg, makes judgments based on the preset process safety rule library, and finally sends the generated emergency command to the seamless switching execution module. The core judgment logic is to assess whether the equipment was in a safe and sustainable operating condition before the fault, and to make the assessment by calculating the safe and sustainable coefficient Ksafe.

[0016] Furthermore, after calculating the safe continuation coefficient Ksafe, it is compared with the preset safety threshold Kth. If Ksafe≥Kth, an automatic continuation command is generated; if Ksafe<Kth, a manual standby command is generated, and the emergency ready indicator light on the on-site operation column is lit, waiting for manual confirmation.

[0017] Furthermore, the seamless switching execution module contains a high-speed electronic switch array and a high-precision analog output unit; under normal circumstances, the high-speed electronic switch conducts the control signal of the main control system to the frequency converter;

[0018] When an automatic continuation command is received, the high-speed electronic switch disconnects from the main control system within 10ms and connects the internal high-precision analog output unit. The high-precision analog output unit immediately outputs an analog signal corresponding to the target frequency Favg in the command to the analog input terminal of the frequency converter, driving the frequency converter to smoothly accelerate or decelerate to Favg.

[0019] When a manual standby command is received, only the control switch is completed, and the manual control permission of the field operation column is activated, waiting for the operator to intervene through the potentiometer or button.

[0020] Furthermore, both the operational situation awareness module and the seamless switching execution module are communicatively connected to the linkage security verification module. The linkage security verification module is activated after the seamless switching execution module takes action to perform a secondary verification of the device status after the emergency start-up.

[0021] Furthermore, the specific operation process of the linkage security verification module is as follows:

[0022] Calculate the current change rate DIrate before and after emergency start-up, and compare the current change rate DIrate with the preset current impact threshold DIlmt. If DIrate ≤ DIlmt, output a safety confirmation signal and end the emergency process; if DIrate > DIlmt, send an emergency stop command to the seamless switching execution module and trigger an audible and visual alarm to notify maintenance personnel to intervene.

[0023] Compared with the prior art, the beneficial effects of the present invention are:

[0024] 1. In this invention, by monitoring the operating status of the main control system in real time, the control authority can be quickly and seamlessly switched when the main control fails, which greatly reduces unplanned downtime and avoids the interruption of the entire production line caused by the failure of a single piece of equipment. Furthermore, by quantifying the operating risk through the safety continuation coefficient, it can intelligently distinguish between two emergency modes: automatic continuation and manual standby, adapting to the differentiated handling needs of different load conditions, and achieving a high degree of intelligence in emergency control.

[0025] 2. In this invention, by configuring a linkage safety verification module, the impact amplitude of the equipment is verified by the current change rate after the switch is completed. When the current impact exceeds the standard, the machine will automatically stop in an emergency and trigger an audible and visual alarm. The dual safety judgment mechanism effectively avoids secondary accidents such as overload and mechanical impact. It is compatible with existing equipment such as PLC and frequency converter on site, and does not require large-scale hardware modification, so the cost of implementation and modification is low. Attached Figure Description

[0026] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings;

[0027] Figure 1 This is a schematic diagram of the overall system structure of the present invention;

[0028] Figure 2 This is a schematic diagram of the operation method of the present invention. Detailed Implementation

[0029] 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.

[0030] Reference Figure 1-2 As shown, the present invention proposes an intelligent emergency control system for linkage equipment, including an operation status awareness module, an emergency strategy generation module, a seamless switching execution module, and a linkage safety verification module; the operation status awareness module monitors the health status of the main control system in an all-round and high-frequency manner, and outputs fault snapshot data packets to the emergency strategy generation module to provide a data basis for subsequent emergency decision-making;

[0031] Specifically, the operation status awareness module continuously monitors the heartbeat signal and communication status from the main control system. At the same time, it reads the inverter's output frequency Fout and output current Iout in real time through an independent I / O channel or communication link.

[0032] When the heartbeat signal of the main control system (PLC / DCS) is lost or communication timeout is detected, the current time t0 is immediately locked, and the average output frequency Favg and average output current Iavg in the previous stable operating cycle before time t0 are recorded, and these parameters are encapsulated into a fault snapshot data packet.

[0033] It should be noted that the average output frequency Favg is calculated as follows: Favg=(ΣFout(i)) / N; where Fout(i) is the output frequency of the i-th sampling point in the previous stable period before time t0, and N is the total number of sampling points in the previous stable period before time t0; the average output current Iavg is calculated in the same way as the average output frequency Favg.

[0034] The emergency strategy generation module analyzes and generates strategies based on fault snapshot data packets, and outputs automatic continuation instructions or manual standby instructions to the seamless switching execution module. It can intelligently select automatic continuation or manual standby strategies according to the operating conditions before the equipment failure, avoiding the "one-size-fits-all" emergency mode. It is highly adaptable and intelligent.

[0035] Specifically, the emergency strategy generation module first receives the fault snapshot data packet, parses out the average output frequency Favg and the average output current Iavg, then makes a judgment based on the preset process safety rule library, and finally sends the generated emergency command to the seamless switching execution module.

[0036] It should be noted that the core judgment logic is to assess whether the equipment was in a safe and sustainable operating condition before the failure: it is assessed by calculating the safe and sustainable coefficient Ksafe, and the calculation formula is: Ksafe=(Favg / Fmax)×α+(Imax-Iavg) / Imax×β;

[0037] Where Fmax is the maximum allowable frequency of the inverter drive equipment, which is a preset constant; Imax is the rated current of the equipment, which is a preset constant; α and β are weighting coefficients, and α+β=1, which can be adjusted according to the importance of different equipment (for example, for flow pumps, α can be set to 0.7; for high torque equipment, β can be set to 0.7).

[0038] After calculating the safe extension coefficient Ksafe, compare the calculated safe extension coefficient Ksafe with the preset safe threshold Kth, as shown below:

[0039] If Ksafe≥Kth, it indicates that the equipment was running smoothly before the failure, the load was moderate, and it was suitable for automatic continuation. In this case, an automatic continuation command is generated, and the average output frequency Favg is packaged together as the target frequency value.

[0040] If Ksafe < Kth, it indicates that the equipment may be under high load or unstable conditions, and the risk of automatic continuation is high. In this case, a manual standby command is generated, and the emergency ready indicator light on the field operation column is lit, waiting for manual confirmation.

[0041] The seamless switching execution module automatically executes emergency commands issued by the emergency strategy generation module, and is responsible for completing the switch of control within milliseconds. The fast response speed wins valuable time for the repair of the main system. Furthermore, by automatically capturing the operating parameters before the fault and achieving seamless switching, it minimizes unplanned downtime, avoids production chain interruptions caused by the downtime of a single piece of equipment, and has significant economic benefits, ensuring production continuity.

[0042] Specifically, the seamless switching execution module contains a high-speed electronic switch array and a high-precision analog output unit; under normal circumstances, the high-speed electronic switch conducts the control signal of the main control system to the frequency converter;

[0043] When an automatic continuation command is received, the high-speed electronic switch disconnects from the main control system within 10ms and connects the internal high-precision analog output unit. The high-precision analog output unit immediately outputs an analog signal corresponding to the target frequency Favg in the command to the analog input terminal of the frequency converter, driving the frequency converter to smoothly accelerate or decelerate to Favg, achieving seamless switching.

[0044] When a manual standby command is received, only the control switch is completed, and the manual control permission of the field operation column is activated, waiting for the operator to intervene through the potentiometer or button.

[0045] The linkage safety verification module is activated after seamlessly switching the execution module's actions. It performs a secondary confirmation of the equipment status after the emergency start-up. By introducing a dual judgment mechanism of "safety continuation coefficient" and "linkage safety verification", it ensures that the emergency operation itself is safe and controllable, effectively preventing the occurrence of secondary accidents.

[0046] Specifically, the linkage safety verification module first obtains the real-time current Ireal of the device at time t1 (preferably 5 seconds after the switch) after the switch from the operation status awareness module. Then, it calculates the current change rate DIrate before and after the emergency start. The calculation formula is: DIrate=|Ireal-Iavg| / Iavg.

[0047] The current change rate DIrate is compared with the preset current surge threshold DIlmt (e.g., 0.3, i.e., 30%), as shown below:

[0048] If DIrate≤DIlmt, it indicates that the emergency start-up process was smooth and did not cause excessive impact on the power grid and equipment. In this case, a safety confirmation signal is output and the emergency process ends.

[0049] If DIrate > DIlmt, it indicates that the emergency start may have caused an overload or mechanical shock. An emergency stop command is immediately sent to the seamless switching execution module, and an audible and visual alarm is triggered to notify maintenance personnel to intervene. This effectively avoids the risk of the accident escalating due to a forced emergency start when there is already a hidden fault in the equipment itself.

[0050] The working principle of this invention is as follows: During use, the operating situation awareness module monitors the heartbeat and communication status of the main control system in real time. When the main control fails, a fault snapshot data packet is immediately generated. The emergency strategy generation module calculates the safety continuation coefficient to assess the risk of the operating condition and intelligently outputs automatic continuation or manual standby instructions. The seamless switching execution module completes the control switch within 10ms through a high-speed electronic switch. In automatic mode, it outputs a matching analog signal to maintain the stable operation of the equipment under the original operating conditions. In manual mode, it activates the on-site operation authority, minimizing unplanned downtime and avoiding the transmission of single equipment failures to the entire production chain. After switching, the linkage safety verification module performs a secondary safety verification based on the current change rate. Based on the dual safety verification mechanism, it effectively prevents secondary accidents such as overload and mechanical shock caused by emergency switching. It is compatible with existing main control and frequency converter architectures, is easy to modify, and has outstanding production assurance and safety protection value.

[0051] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, enabling those skilled in the art to better understand and utilize it. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. An intelligent emergency control system for interconnected equipment, characterized in that, It includes an operational situation awareness module, an emergency strategy generation module, and a seamless switching execution module; The operational situation awareness module monitors the health status of the main control system in a comprehensive and high-frequency manner, and outputs fault snapshot data packets to the emergency strategy generation module; The emergency strategy generation module analyzes and generates strategies based on fault snapshot data packets, and outputs automatic continuation instructions or manual standby instructions to the seamless switching execution module. Seamlessly switch execution modules to automatically execute emergency commands issued by the emergency strategy generation module.

2. The intelligent emergency control system for linkage equipment according to claim 1, characterized in that, The operation process of the situational awareness module includes: When the heartbeat signal of the main control system is lost or communication timeout is detected, the current time t0 is immediately locked, and the average output frequency Favg and average output current Iavg in the previous stable operating cycle before time t0 are recorded, and these parameters are encapsulated into a fault snapshot data packet.

3. The intelligent emergency control system for linkage equipment according to claim 2, characterized in that, The average output current Iavg and the average output frequency Favg are calculated in the same way, and the average output frequency Favg is calculated as follows: Favg=(ΣFout(i)) / N; where Fout(i) is the output frequency of the i-th sampling point in the previous stable period before time t0, and N is the total number of sampling points.

4. The intelligent emergency control system for linkage equipment according to claim 1, characterized in that, The emergency strategy generation module analyzes and generates strategies based on fault snapshot data packets as follows: The system receives fault snapshot data packets, parses out the average output frequency Favg and average output current Iavg, makes judgments based on the preset process safety rule library, and finally sends the generated emergency command to the seamless switching execution module. The core judgment logic is to assess whether the equipment was in a safe and sustainable operating condition before the fault, and to make the assessment by calculating the safe and sustainable coefficient Ksafe.

5. The intelligent emergency control system for linkage equipment according to claim 4, characterized in that, After calculating the safe continuation coefficient Ksafe, it is compared with the preset safety threshold Kth. If Ksafe≥Kth, an automatic continuation command is generated; if Ksafe<Kth, a manual standby command is generated, and the emergency ready indicator light on the on-site operation column is lit, waiting for manual confirmation.

6. The intelligent emergency control system for linked equipment according to claim 4, characterized in that, The seamless switching execution module contains a high-speed electronic switch array and a high-precision analog output unit; under normal circumstances, the high-speed electronic switch conducts the control signal of the main control system to the frequency converter; When an automatic continuation command is received, the high-speed electronic switch disconnects from the main control system within 10ms and connects the internal high-precision analog output unit. The high-precision analog output unit immediately outputs an analog signal corresponding to the target frequency Favg in the command to the analog input terminal of the frequency converter, driving the frequency converter to smoothly accelerate or decelerate to Favg. When a manual standby command is received, only the control switch is completed, and the manual control authority of the field operation column is activated, waiting for the operator to intervene via potentiometer or button.

7. The intelligent emergency control system for linked equipment according to claim 1, characterized in that, Both the operational situation awareness module and the seamless switching execution module are communicatively connected to the linkage security verification module. The linkage security verification module is activated after the seamless switching execution module takes action to perform a secondary verification of the device status after the emergency start-up.

8. The intelligent emergency control system for linkage equipment according to claim 7, characterized in that, The specific operation process of the linkage security verification module is as follows: Calculate the current change rate DIrate before and after emergency start-up, and compare the current change rate DIrate with the preset current impact threshold DIlmt. If DIrate ≤ DIlmt, output a safety confirmation signal and end the emergency process; if DIrate > DIlmt, send an emergency stop command to the seamless switching execution module and trigger an audible and visual alarm to notify maintenance personnel to intervene.

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