Movable secondary pump station power distribution and control system and migration method thereof

Abstract

The present application relates to a kind of movable secondary pump station distribution and control system and its migration method, for overburden strata separation grouting, system includes distribution power module, mobile secondary pump station and intelligent control module, three are independent modular movable shell.Distribution power module is integrated with high-voltage distribution cabinet, high-voltage driving device, transformer, low-voltage distribution cabinet and control master station in, and introduce the external interface of a way external power supply.Movable secondary pump station is equipped with grouting pump and control substation;The control device of grouting pump and control substation are respectively connected with control master station by communication cable communication connection.Intelligent control module is equipped with host computer, and host computer is connected with control master station by communication cable communication connection.Three modules are connected by detachable power cable and communication cable;The control cable and signal cable pre-laid in each shell remain original connection state after adjacent shell connection is disconnected.Migration only needs to plug the detachable cable between modules, and cable in shell does not need to be disassembled.

Description

Technical Field

[0001] This invention relates to the field of grouting and filling technology for coal mine overburden separation, and in particular to a mobile secondary pump station power distribution and control system and its relocation method. Background Technology

[0002] Overburden separation grouting is a key technology for green coal mining that involves injecting grout material into the overburden separation space during mining to control surface subsidence and achieve safe coal mining under three conditions (under buildings, railways, and water bodies).

[0003] In the application of delamination grouting technology, when the distance between the grouting system and the grouting borehole exceeds 4 kilometers, the resistance to grout delivery is relatively large. Generally, two-stage pumping stations are required for grout delivery. The secondary pumping station is responsible for further pressurizing and delivering the grout prepared by the grouting system to the grouting borehole. To ensure the filling effect, the location of the secondary pumping station needs to be dynamically adjusted according to the changes in the grouting point.

[0004] However, existing secondary pumping stations mostly employ permanent or semi-permanent building structures, which face multiple challenges in practical applications. On the one hand, from the perspective of land acquisition policy, with the dynamic adjustment of grouting areas, frequent relocation of pumping stations requires repeated coordination of land use approval procedures. Especially in areas with complex land ownership or strict policy controls, the process for selecting permanent or semi-permanent land acquisition sites is complex and difficult to approve. Moreover, it is difficult to reuse the original infrastructure during relocation, resulting in resource waste. On the other hand, the relocation of the supporting power distribution and control systems during the relocation of secondary pumping stations is even more difficult—it requires the dismantling of a large number of power cables, control cables, signal cables, high-voltage distribution cabinets, low-voltage distribution cabinets, control cabinets, instruments, valves, and other equipment and lines, resulting in a huge workload. Furthermore, the equipment is easily damaged during dismantling and transportation. Reinstallation requires extensive wiring and debugging work again, which is costly and inefficient. Summary of the Invention

[0005] The purpose of this invention is to provide a portable secondary pumping station power distribution and control system and its relocation method, so as to solve the problems of large relocation workload, complex and error-prone on-site wiring, and easy equipment damage caused by the existing overburden separation grouting secondary pumping station power distribution and control system.

[0006] To achieve the above objectives, the present invention provides a mobile secondary pump station power distribution and control system for grouting of overburden separation, comprising a power distribution module, a mobile secondary pump station, and an intelligent control module, wherein the power distribution module, the mobile secondary pump station, and the intelligent control module are each independent modular movable housings;

[0007] The housing of the power distribution module integrates a high-voltage distribution cabinet, a high-voltage drive device, a transformer, a low-voltage distribution cabinet, and a control master station. The control circuit of the high-voltage drive device is electrically connected to the control master station. The low-voltage distribution cabinet provides power to the mobile secondary pump station via a power cable. The power distribution module has an external power interface for introducing an external power source.

[0008] The mobile secondary pumping station is equipped with a grouting pump and a control substation inside its casing. The main motor of the grouting pump is electrically connected to the high-voltage distribution cabinet through the high-voltage drive device. The grouting pump and the control substation are respectively connected to the control master station through communication cables.

[0009] The intelligent control module is equipped with a host computer, which is connected to the control master station via a communication cable.

[0010] The power distribution module, the mobile secondary pump station, and the intelligent control module are electrically and communicatively connected via detachable power cables and communication cables. Furthermore, the control cables and signal cables pre-laid in each modular movable housing maintain their original connection status after the connection between adjacent modular movable housings is broken.

[0011] Optionally, the modular movable shell is a skid-mounted container structure.

[0012] Optionally, the grouting pump has its own control box, and the control box of the grouting pump is connected to the control master station via a communication cable.

[0013] Optionally, the high-voltage drive device is a high-voltage soft-start integrated machine.

[0014] Optionally, the low-voltage distribution cabinet includes a low-voltage main cabinet and a low-voltage outgoing cabinet. The power distribution module housing also includes a transformer outgoing cabinet. The incoming terminal of the high-voltage distribution cabinet is connected to the external power interface. The outgoing terminals of the high-voltage distribution cabinet are respectively connected to the high-voltage soft starter and the transformer outgoing cabinet. The transformer outgoing cabinet is connected to the high-voltage side of the transformer. The low-voltage side of the transformer is connected to the low-voltage main cabinet. The low-voltage main cabinet provides power to the mobile secondary pump station through the low-voltage outgoing cabinet.

[0015] Optionally, both the control master station and the control substation are equipped with PLC controllers, and the PLC controllers of the two units form a distributed PLC control system through a communication network.

[0016] Optionally, the control substation is connected to the valves, measuring devices, heat tracing equipment, air conditioning and ventilation equipment inside the shell of the mobile secondary pump station via internal control cables and power lines.

[0017] Optionally, the intelligent control module is set up independently of the power distribution module and the mobile secondary pump station; when multiple mobile secondary pump stations are configured on the same grouting working face, the intelligent control module is connected to the control master station corresponding to each mobile secondary pump station through a communication network to centrally monitor the multiple mobile secondary pump stations.

[0018] Optionally, the intelligent control module is equipped with a switch, and when a new mobile secondary pumping station is added, the intelligent control module connects to the control master station corresponding to the newly added mobile secondary pumping station through the switch.

[0019] Based on the same inventive concept, the present invention also provides a relocation method for a power distribution and control system of a mobile secondary pumping station as described above, comprising the following steps:

[0020] Disconnect each modular movable shell from its respective base;

[0021] Disconnect the power and communication cables between adjacent modular movable housings;

[0022] Maintain the original connection status of the control cables and signal cables pre-laid in each modular movable housing, without disassembling them;

[0023] The power distribution module, mobile secondary pump station, and intelligent control module were each hoisted and positioned at the new grouting location.

[0024] Reconnect the power and communication cables between adjacent modular movable housings and restore the fixed connection between each modular movable housing and the foundation;

[0025] Restore external power supply through the external power interface to put the system back into operation.

[0026] The mobile secondary pumping station power distribution and control system and its relocation method provided by the present invention have at least one of the following beneficial effects:

[0027] 1) For the relocation of a secondary grouting station, the power distribution and control system consists of three independent modular movable shells (such as skid-mounted container structures). The control and signal cables pre-laid within each shell maintain their original connections after the connections between adjacent shells are disconnected. During relocation, only the detachable power and communication cables between adjacent shells, as well as the fixed connections between each shell and the foundation, need to be disconnected, allowing each module to be lifted and transported as a whole. Compared to traditional solutions that require extensive dismantling and re-laying of various cables, power distribution equipment, and control equipment, this solution helps reduce dismantling workload, lowers the risk of equipment damage during dismantling and transportation, and thus saves relocation costs.

[0028] 2) The main control station is integrated within the housing of the power distribution module, while the sub-control stations are integrated within the housing of the mobile secondary pump station. These two systems form a distributed PLC control system via a communication network. During relocation, the pre-installed control and signal cables within each housing remain unchanged. After repositioning, only the power and communication cables between adjacent housings need to be reconnected to restore system operation. This reduces on-site wiring, helps lower the possibility of wiring errors, improves system stability after re-commissioning, increases installation efficiency, reduces reinstallation costs, and achieves a "plug-and-play" rapid migration effect.

[0029] 3) The intelligent control module is independent of the power distribution module and the mobile secondary pump station. It supports connection to the control master station corresponding to multiple mobile secondary pump stations via a communication network, realizing one-to-many centralized monitoring. The host computer of the intelligent control module is connected to the built-in switch via a network cable. When a new mobile secondary pump station needs to be added to the same working area, the control master station of the new pump station only needs to be connected to an unused port of the switch via a network cable, and the corresponding monitoring screen and parameter configuration can be expanded in the host computer monitoring software to complete the access of the new pump station, realize one-to-many centralized monitoring, and the hardware resources can be shared by multiple pump stations, which is flexible and conducive to saving hardware costs. Attached Figure Description

[0030] Those skilled in the art will understand that the accompanying drawings are provided to better understand the invention and do not constitute any limitation on the scope of the invention. Wherein:

[0031] Figure 1 This is an overall structural block diagram of a mobile secondary pumping station power distribution and control system provided in an embodiment of the present invention;

[0032] Figure 2 This is a block diagram of the internal structure of a power distribution module provided in an embodiment of the present invention;

[0033] Figure 3 This is a communication connection diagram of a mobile secondary pumping station power distribution and control system provided in an embodiment of the present invention.

[0034] The attached figures are labeled as follows:

[0035] 100 - Power distribution module; 110 - High-voltage distribution cabinet; 120 - High-voltage drive device; 130 - Transformer; 140 - Low-voltage distribution cabinet; 141 - Low-voltage main receiving cabinet; 142 - Low-voltage outgoing cabinet; 150 - Control master station; 160 - Transformer outgoing cabinet; 200 - Mobile secondary pump station; 210 - Grouting pump; 220 - Control substation; 300 - Intelligent control module; 310 - Host computer; 320 - Switch. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0037] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0038] In the description of this invention, it should be understood that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are only used to facilitate the description of this invention and to simplify the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0039] Furthermore, relational terms such as "first" and "second" are used merely 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. Moreover, 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 an article or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the article or apparatus that includes said element. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0040] Please refer to Figures 1-3 This invention provides a mobile secondary pump station power distribution and control system for grouting overburden separation, including a power distribution module 100, a mobile secondary pump station 200, and an intelligent control module 300. The power distribution module 100, the mobile secondary pump station 200, and the intelligent control module 300 are each independent modular mobile housings.

[0041] The power distribution module 100 integrates a high-voltage distribution cabinet 110, a high-voltage drive device 120, a transformer 130, a low-voltage distribution cabinet 140, and a control master station 150 within its housing. The control circuit of the high-voltage drive device 120 is electrically connected to the control master station 150. The low-voltage distribution cabinet 140 provides power to the mobile secondary pump station 200 via a power cable. The power distribution module 100 has an external power interface for introducing an external power source.

[0042] The mobile secondary pump station 200 is equipped with a grouting pump 210 and a control substation 220 inside its casing. The main motor of the grouting pump 210 is electrically connected to the high-voltage distribution cabinet 110 through a high-voltage drive device 120. The grouting pump 210 and the control substation 220 are respectively connected to the control master station 150 through communication cables.

[0043] The intelligent control module 300 is equipped with a host computer 310, which is connected to the control master station 150 via a communication cable.

[0044] Among them, the power distribution module 100, the mobile secondary pump station 200 and the intelligent control module 300 are electrically and communicationly connected through detachable power cables and communication cables; and the control cables and signal cables pre-laid in each modular movable housing maintain their original connection state after the connection between adjacent modular movable housings is broken.

[0045] This embodiment provides a mobile secondary pumping station power distribution and control system for overburden separation grouting operations. The system consists of three functional modules: a power distribution module 100, a mobile secondary pumping station 200, and an intelligent control module 300. Each of these three modules is encapsulated in an independent modular mobile housing, and each housing can be transported, hoisted, and positioned separately.

[0046] The power distribution module 100 integrates a high-voltage distribution cabinet 110, a high-voltage drive unit 120, a transformer 130, a low-voltage distribution cabinet 140, and a control master station 150 within its housing. The high-voltage distribution cabinet 110 connects to an external high-voltage power source. The high-voltage drive unit 120 drives the main motor of the grouting pump 210. The transformer 130 steps down the high-voltage power supply to low-voltage equipment. The low-voltage distribution cabinet 140 distributes low-voltage power. The control master station 150 serves as the control core of the power distribution module 100. The control circuit of the high-voltage drive unit 120 is electrically connected to the control master station 150, enabling the control master station 150 to send start / stop and speed control commands to the high-voltage drive unit 120. The low-voltage distribution cabinet 140 provides power to the mobile secondary pump station 200 via a power cable. An external power interface is installed on the housing of the power distribution module 100 to allow the introduction of an external power source from the field. After the external power supply enters the power distribution module 100, it is first connected to the high-voltage distribution cabinet 110. The outgoing terminals of the high-voltage distribution cabinet 110 are connected to the high-voltage drive device 120 and the transformer 130 respectively. The transformer outgoing cabinet is connected to the high-voltage side of the transformer. Thus, the high-voltage drive device can be powered by one external power input, and after being stepped down by the transformer 130, the low-voltage equipment in the system is powered, so that one power input can cover the power demand of the entire system.

[0047] In practical implementation, the preferred voltage level of the external power supply is 10kV, and the external power interface is equipped with a 10kV cable entry device. The power distribution module 100 integrates a 10kV high-voltage distribution cabinet 110, a 10kV high-voltage drive device 120, a 10 / 0.4kV transformer 130, an AC380V low-voltage distribution cabinet 140, and a control master station 150. Only one 10kV power supply from the substation is needed to meet the power distribution requirements of all voltage levels of equipment and control systems in the mobile secondary pump station 200 and the intelligent control module 300, including voltage levels such as 10kV, AC380V, AC220V, and DC24V.

[0048] The mobile secondary pumping station 200 houses a grouting pump 210 and a control substation 220. The main motor of the grouting pump 210 is electrically connected to a high-voltage distribution cabinet 110 via a high-voltage drive device 120. The electrical energy output from the high-voltage distribution cabinet 110 is adjusted by the high-voltage drive device 120 and then drives the main motor of the grouting pump 210. The grouting pump 210 and the control substation 220 are respectively connected to a control master station 150 via communication cables. This allows the control master station 150 to acquire the operating status of the grouting pump 210 and issue control commands, while the control substation 220 can also upload collected field signals to the control master station 150.

[0049] The intelligent control module 300 contains a host computer 310, which is connected to the control master station 150 in the power distribution module 100 via a communication cable, thereby realizing human-machine interaction, data acquisition, and centralized monitoring functions. Furthermore, the intelligent control module 300 has a power interface inside its housing, which is connected to the low-voltage distribution cabinet 140 of the power distribution module 100 via a detachable power cable (such as an AC220V power cord), providing operating power to the intelligent control module 300.

[0050] Electrical and communication connections between the three modules are established via detachable power and communication cables. Specifically, quick-connect sockets or aviation plugs are provided at the interfaces of adjacent movable modules. The two ends of the power and communication cables are connected to the corresponding movable sockets of the modules via plugs. When relocation is required, the plugs can be unplugged to disconnect the connection, and the plugs can be plugged back in to restore the connection.

[0051] Preferably, the connectors for power cables and communication cables between adjacent modules employ industrial-grade quick-connect interfaces. The power cable connectors are preferably industrial-grade multi-core aviation plugs with a rated current of not less than 250A, featuring a key design to prevent mis-mating, thus preventing incorrect insertion of cables with different phase sequences or voltage levels. The communication cable connectors use shielded RJ45 waterproof plugs or fiber optic quick connectors, supporting Gigabit Ethernet transmission to ensure communication signal stability and anti-interference capabilities. All connectors meet IP65 or higher protection standards, effectively preventing dust and water intrusion and adapting to harsh environmental conditions such as humid, dusty conditions in coal mines or outdoor heavy rain. The connector mating life is not less than 500 cycles, meeting the requirements for multiple relocations and reuses.

[0052] Each modular movable housing has all control and signal cables pre-laid and secured before leaving the factory. These cables include internal control cables between the control master station 150 and the control substation 220, sensor signal lines, and equipment control lines. When the connection between adjacent modular movable housings is broken, the pre-laid control and signal cables in each housing remain in their original connection state without any disassembly operation.

[0053] By dividing the power distribution and control system into three independent movable modules and completing the pre-laying and fixed connection of all control cables and signal cables inside the housing in the factory, field migration only requires plugging and unplugging the detachable power cables and communication cables across the modules. The complex control and signal cables inside the housing do not need to be disassembled at all. This solves the problems of traditional solutions that require a large number of disconnecting and reconnecting cables, are prone to errors, and are time-consuming, achieving a rapid migration effect of "plug and play".

[0054] Preferably, the modular movable shell adopts a skid-mounted container structure. Specifically, each module is encapsulated within a container shell conforming to standard or customized container dimensions. The container has a skid-mounted base at the bottom for easy handling by forklift or crane. The container shell uses a steel frame and sandwich-type color steel plate walls, providing dustproof, rainproof, heat insulation, and explosion-proof functions, meeting the requirements for use in harsh environments such as underground coal mines or open-air environments. The skid-mounted container structure allows for the factory prefabrication and overall encapsulation of power distribution and control equipment. On-site, only the container needs to be hoisted into place and connected to external cables for immediate use, eliminating the need for on-site civil construction, significantly shortening the construction period, and facilitating multiple relocations and reuses.

[0055] In this embodiment, the grouting pump 210 comes with a dedicated control box at the factory. This control box integrates the pump's protection relays, soft starter or frequency converter, local operation buttons, and status indicator lights. The control box communicates with the control master station 150 within the power distribution module 100 via a communication cable, uploading operating parameters such as flow rate, pressure, temperature, and vibration of the grouting pump 210 to the control master station 150 and receiving start / stop and adjustment commands from the control master station 150. By using a self-contained control box, the pump body and control device are tightly integrated, reducing the space required for additional control cabinets on-site. Furthermore, the connection cables between the pump body and the control box are pre-installed at the pump factory, eliminating the need for on-site wiring and further reducing on-site workload. Alternatively, the grouting pump 210 can also use an external, independent control cabinet; this invention does not impose any restrictions on this.

[0056] In this embodiment, the high-voltage drive unit 120 adopts a high-voltage soft starter integrated machine. The high-voltage soft starter integrated machine can achieve a smooth soft start for the main motor of the grouting pump 210, limiting the starting current and reducing the impact on the power grid and mechanical system. The control circuit of the high-voltage soft starter integrated machine is electrically connected to the control master station 150 via a control cable. The control master station 150 can remotely set starting parameters, issue starting commands, and monitor the starting process. In specific implementations, the rated power of the high-voltage soft starter integrated machine is preferably a specification that can match a 450kW main motor, for example, a soft starter integrated machine with a rated output power of 500kW or 630kW.

[0057] The high-pressure soft starter unit is highly integrated and occupies a small area, making it particularly suitable for installation in modular, movable housings with limited space. At the same time, the soft start function effectively protects the main motor and mechanical transmission system of the grouting pump 210, extending the service life of the equipment.

[0058] In this embodiment, the low-voltage distribution cabinet 140 includes a low-voltage receiving cabinet 141 and a low-voltage output cabinet 142. A transformer output cabinet 160 is also installed inside the housing of the power distribution module 100. The incoming terminal of the high-voltage distribution cabinet 110 is connected to an external power interface. The outgoing terminals of the high-voltage distribution cabinet 110 are respectively connected to a high-voltage soft starter and the transformer output cabinet 160. The transformer output cabinet 160 is connected to the high-voltage side of the transformer 130. The low-voltage side of the transformer 130 is connected to the low-voltage receiving cabinet 141. The low-voltage receiving cabinet 141 provides power to the mobile secondary pump station 200 through the low-voltage output cabinet 142.

[0059] The specific power supply chain is as follows: an external 10kV high-voltage power supply is first connected to the 10kV high-voltage incoming line cabinet. The outgoing line of the 10kV high-voltage incoming line cabinet is divided into two paths: one path connects to the high-voltage soft starter integrated machine to drive the main motor of the 450kW grouting pump 210, and the other path connects to the transformer outgoing line cabinet 160. The transformer outgoing line cabinet 160 is equipped with a vacuum circuit breaker or load switch and protection devices to control and protect the high-voltage side of the transformer 130. The transformer 130 is preferably a 10 / 0.4kV dry-type transformer 130, which steps down the 10kV high-voltage electricity to 0.4kV low-voltage electricity. Its low-voltage side output is connected to the low-voltage receiving cabinet 141, which is equipped with a main circuit breaker, ammeter, voltmeter, etc., for summarizing and distributing low-voltage electrical energy. The output terminal of the low-voltage main receiving cabinet 141 is then connected to the low-voltage outgoing cabinet 142, which provides 0.4kV power to the mobile secondary pump station 200 and other low-voltage loads.

[0060] Both the master control station 150 and the substation 220 integrate PLC controllers, which form a distributed PLC control system via a communication network. The PLC controller in the master control station 150 acts as the master controller, responsible for communicating with the host computer 310 of the intelligent control module 300, collecting the status of the high-voltage drive device 120, and managing the low-voltage power distribution circuit. The PLC controller in the substation 220 acts as a slave controller, responsible for collecting signals from various field devices within the mobile secondary pump station 200 and controlling valves, heating equipment, air conditioning, and ventilation equipment. The master and slave PLCs are interconnected via industrial Ethernet or fieldbus communication networks to achieve data exchange and collaborative control.

[0061] In addition, the PLC controller can be replaced with other types of industrial controllers, such as DCS controllers, PAC programmable automation controllers, or embedded industrial PCs. The communication network can adopt industrial communication protocols such as Profibus-DP, Modbus RTU, Modbus TCP, and CANopen. Wireless communication, such as industrial WiFi or a 5G private network, can also be used between the control master station 150 and the control substation 220.

[0062] In practical implementation, the PLC controller in the control master station 150 can collect the operating parameters of the high-voltage drive device 120, including but not limited to three-phase current, three-phase voltage, number of starts, cumulative running time, and fault codes, and upload them to the host computer 310 for centralized display and recording via communication cable. The control master station 150 can send start, stop, and emergency stop commands to the high-voltage drive device 120. The PLC controller in the control substation 220 is connected to the field equipment in the mobile secondary pump station 200 through pre-laid internal control cables and signal cables. It collects 4-20mA or 0-10V standard signals from level gauges, pressure gauges, flow meters, temperature sensors, and smoke sensors through analog input modules, and monitors the slurry level, pipeline pressure, slurry flow rate, equipment temperature, and smoke concentration in real time; and controls the opening and closing of valves, the start and stop of heating tape, the switching of air conditioning cooling or heating modes, and the operation of ventilation equipment. For example, when the temperature sensor detects that the temperature inside the housing is lower than a set threshold, the control substation 220 automatically starts the heating cable and air conditioning system; when the smoke sensor detects that the smoke concentration exceeds the standard, the control substation 220 immediately cuts off the power supply to the relevant equipment and starts the ventilation equipment to exhaust smoke. The above control logic is pre-programmed into the PLC controller before leaving the factory and does not require reconfiguration on site.

[0063] Preferably, the control substation 220 is connected to valves, measuring devices, heat tracing equipment, air conditioning, and ventilation equipment within the housing of the mobile secondary pumping station 200 via internal control cables and power lines. Specifically, the I / O interface of the control substation 220 is connected via pre-laid internal control cables and power lines to various valves (such as electric gate valves, check valves, bypass valves, etc. on slurry pipelines), measuring devices (such as various sensors for measuring slurry level, pressure, and flow rate, specifically level gauges, pressure gauges, flow meters, etc.), heat tracing equipment (such as electric heat tracing cables for preventing slurry freezing in winter), air conditioning equipment (for regulating the internal temperature of the housing), and ventilation equipment (such as explosion-proof exhaust fans). By collecting signals from these devices and executing control outputs, the control substation 220 achieves automatic adjustment of the internal environment and process parameters of the mobile secondary pumping station 200.

[0064] All auxiliary equipment within the control substation and the mobile secondary pump station 200 are directly connected via pre-laid internal cables. These cables can be terminated in the factory, eliminating the need for any on-site wiring operations and ensuring plug-and-play functionality for the auxiliary equipment. This further reduces on-site construction work and potential points of failure.

[0065] The intelligent control module 300 is independent of the power distribution module 100 and the mobile secondary pumping station 200. Specifically, the intelligent control module 300 is encapsulated in a separate housing, which is physically separate from the housings of the power distribution module 100 and the mobile secondary pumping station 200, allowing it to be placed in different locations according to site requirements. When multiple mobile secondary pumping stations 200 are configured on the same grouting working face, the intelligent control module 300 connects to the corresponding control master station 150 of each mobile secondary pumping station 200 via a communication network, thereby achieving centralized monitoring of multiple mobile secondary pumping stations 200. In specific implementation, the physical medium of the communication network is preferably a network cable, meaning the intelligent control module 300 only needs a network cable to establish a communication connection with each control master station 150, greatly simplifying on-site wiring. The host computer 310 within the intelligent control module 300 runs monitoring software, which can simultaneously display the operating parameters, alarm information, and historical curves of each pumping station, and can send control commands to each pumping station through the same operating interface. The intelligent control module 300 is independently configured and supports one-to-many centralized monitoring, allowing multiple mobile secondary pump stations 200 on the same grouting working face to share a single intelligent control hardware resource, significantly reducing hardware costs when configuring multiple pump stations. Furthermore, adding or removing a pump station only requires adding or deleting a node on the communication network, making expansion extremely flexible and truly realizing a "plug-and-play" centralized monitoring architecture.

[0066] The intelligent control module 300 is equipped with a switch 320. When a new mobile secondary pumping station 200 is added, the intelligent control module 300 connects to the corresponding control master station 150 of the new mobile secondary pumping station 200 through the switch 320. Specifically, the host computer 310 of the intelligent control module 300 is connected to the built-in switch 320 via a network cable. When it is necessary to add a mobile secondary pumping station 200 to the same work surface, it is only necessary to connect the control master station 150 of the new pumping station to an unused port of the switch 320 via a network cable, and expand the corresponding monitoring screen and parameter configuration in the monitoring software of the host computer 310 to complete the access of the new pumping station without replacing any hardware equipment.

[0067] The switch 320 can be either an industrial-grade managed switch 320 or an unmanaged switch 320, with the number of ports selected according to actual needs, such as 8, 16, or 24 ports. When adding a new pump station, in addition to network cables, single-mode or multi-mode fiber optic cables can also be used for connection, to meet the needs of long-distance communication. The monitoring screen can be expanded through automatic device discovery and addition, or through manual configuration.

[0068] Based on the same inventive concept, this invention also proposes a migration method for the power distribution and control system of the mobile secondary pumping station described above, comprising the following steps:

[0069] S1. Disconnect the fixed connections between each modular movable shell and its respective foundation. After each modular movable shell is in place, it is fixed to the on-site foundation by anchor bolts or welding. Before relocation, loosen or cut these fixed connections to separate the shell from the foundation.

[0070] S2. Disconnect the power and communication cables between adjacent modular movable housings. The operator should unplug the detachable power and communication cables connected to the interfaces of each module to completely disconnect the electrical and communication connections between the modules.

[0071] S3. Maintain the original connection status of the control cables and signal cables pre-laid in each modular movable housing without disassembling them. This is the core step of the invention—since all control cables and signal cables in each modular movable housing have been pre-laid and fixedly connected at the factory, these cables remain properly connected to the internal equipment and do not require any disconnection.

[0072] S4. The power distribution module 100, the mobile secondary pump station 200, and the intelligent control module 300 are hoisted as a whole to the new grouting location and positioned. Using a crane or forklift, the three independent modular movable shells are hoisted onto transport vehicles, transported to the new grouting working surface, and then hoisted onto the pre-prepared new foundation.

[0073] S5. Reconnect the power and communication cables between adjacent modular movable housings and restore the fixed connection between each modular movable housing and the foundation. After positioning each module, insert the plugs of the power and communication cables into the sockets of the corresponding housings to restore the electrical and communication connections between the modules. At the same time, use anchor bolts and other fasteners to re-secure each housing to the foundation.

[0074] S6. Restore the external power supply introduced through the external power interface to put the system back into operation. Connect the external power line back to the external power interface of the power distribution module 100, close the switch to supply power, and the system will resume normal operation.

[0075] In addition to anchor bolts, the modular movable housings can also be fixed to the foundation using expansion bolts, welding, or counterweights. For lifting, in addition to crane hoisting, lighter modules can be directly handled by forklift. When disconnecting and reconnecting power and communication cables, in addition to using plugs and sockets, quick-connect terminals or crimped connectors can also be used.

[0076] The entire migration process does not require disassembling any control cables and signal cables inside the casing. Only a small number of power cables and communication cables between modules need to be disconnected and reconnected. The migration workload is greatly reduced, and the downtime is shortened from several days to several hours, which greatly improves the construction efficiency and equipment reuse rate of the overburden separation grouting project.

[0077] In summary, this invention provides a mobile secondary pumping station power distribution and control system and its relocation method. The power distribution module, the mobile secondary pumping station 200, and the intelligent control module are divided into three independent modular mobile housings. The necessary control and signal cables within each housing are pre-laid and fixedly connected in the factory. During relocation, the original cable connections within the housings are maintained. Only the detachable power and communication cables between adjacent housings need to be disconnected and reconnected, enabling rapid disassembly and reconfiguration of the system. This helps reduce on-site wiring work, lowers the risk of equipment damage during transport, and saves relocation costs. Furthermore, the intelligent control module 300 is set independently of the power distribution module 100 and the mobile secondary pumping station 200, and supports connection to the control master station 150 corresponding to multiple mobile secondary pumping stations 200 via a communication network, achieving one-to-many centralized monitoring. The host computer 310 of the intelligent control module 300 is connected to the built-in switch 320 via a network cable. When a mobile secondary pump station 200 needs to be added to the same working surface, the control master station 150 of the new pump station only needs to be connected to an idle port of the switch 320 via a network cable, and the corresponding monitoring screen and parameter configuration can be expanded in the monitoring software of the host computer 310 to complete the access of the new pump station, realize one-to-many centralized monitoring, and the hardware resources can be shared by multiple pump stations. The expansion is flexible and helps to save hardware costs.

[0078] The above description is merely a description of preferred embodiments of the present invention and is not intended to limit the scope of the invention in any way. Any changes or modifications made by those skilled in the art based on the above disclosure are within the protection scope of the present invention. Obviously, those skilled in the art can make various modifications and variations to the present invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the present invention and its equivalents, the present invention also intends to include these modifications and variations.

Claims

1. A portable secondary pump station power distribution and control system for grouting overburden separation, characterized in that, It includes a power distribution module, a mobile secondary pumping station, and an intelligent control module, each of which is a separate modular movable housing. The housing of the power distribution module integrates a high-voltage distribution cabinet, a high-voltage drive device, a transformer, a low-voltage distribution cabinet, and a control master station. The control circuit of the high-voltage drive device is electrically connected to the control master station. The low-voltage distribution cabinet provides power to the mobile secondary pump station via a power cable. The power distribution module has an external power interface for introducing an external power source. The mobile secondary pumping station is equipped with a grouting pump and a control substation inside its casing. The main motor of the grouting pump is electrically connected to the high-voltage distribution cabinet through the high-voltage drive device. The grouting pump and the control substation are respectively connected to the control master station through communication cables. The intelligent control module is equipped with a host computer, which is connected to the control master station via a communication cable. The power distribution module, the mobile secondary pump station, and the intelligent control module are electrically and communicatively connected via detachable power cables and communication cables. Furthermore, the control cables and signal cables pre-laid in each modular movable housing maintain their original connection status after the connection between adjacent modular movable housings is broken.

2. The mobile secondary pumping station power distribution and control system according to claim 1, characterized in that, The modular movable shell is a skid-mounted container structure.

3. The mobile secondary pumping station power distribution and control system according to claim 1, characterized in that, The grouting pump has its own control box, which is connected to the control master station via a communication cable.

4. The mobile secondary pumping station power distribution and control system according to claim 1, characterized in that, The high-voltage drive device is a high-voltage soft-start integrated machine.

5. The mobile secondary pumping station power distribution and control system according to claim 4, characterized in that, The low-voltage distribution cabinet includes a low-voltage main cabinet and a low-voltage outgoing cabinet. The power distribution module housing also contains a transformer outgoing cabinet. The incoming line of the high-voltage distribution cabinet is connected to the external power interface. The outgoing line of the high-voltage distribution cabinet is connected to the high-voltage soft starter and the transformer outgoing cabinet, respectively. The transformer outgoing cabinet is connected to the high-voltage side of the transformer. The low-voltage side of the transformer is connected to the low-voltage main cabinet. The low-voltage main cabinet provides power to the mobile secondary pump station through the low-voltage outgoing cabinet.

6. The mobile secondary pumping station power distribution and control system according to claim 1, characterized in that, Both the main control station and the substations are equipped with PLC controllers, which together form a distributed PLC control system via a communication network.

7. The mobile secondary pumping station power distribution and control system according to claim 1, characterized in that, The control substation is connected to the valves, measuring devices, heat tracing equipment, air conditioning and ventilation equipment inside the shell of the mobile secondary pump station via internal control cables and power lines.

8. The mobile secondary pumping station power distribution and control system according to claim 1, characterized in that, The intelligent control module is set up independently of the power distribution module and the mobile secondary pump station; when multiple mobile secondary pump stations are configured on the same grouting working face, the intelligent control module is connected to the control master station corresponding to each mobile secondary pump station through a communication network to centrally monitor the multiple mobile secondary pump stations.

9. The mobile secondary pumping station power distribution and control system according to claim 8, characterized in that, The intelligent control module is equipped with a switch. When a new mobile secondary pumping station is added, the intelligent control module connects to the control master station corresponding to the newly added mobile secondary pumping station through the switch.

10. A relocation method for a power distribution and control system of a mobile secondary pumping station according to any one of claims 1-9, characterized in that, Includes the following steps: Disconnect each modular movable shell from its respective base; Disconnect the power and communication cables between adjacent modular movable housings; Maintain the original connection status of the control cables and signal cables pre-laid in each modular movable housing, without disassembling them; The power distribution module, mobile secondary pump station, and intelligent control module were each hoisted and positioned at the new grouting location. Reconnect the power and communication cables between adjacent modular movable housings and restore the fixed connection between each modular movable housing and the foundation; Restore external power supply through the external power interface to put the system back into operation.

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