Integrated control system of air compressor station building

Abstract

The utility model relates to the technical field of integrated control circuits, in particular to an integrated control system of an air compressor station building, which comprises a signal converter, an input end of the signal converter is connected with a signal conditioning circuit, the signal conditioning circuit is used for receiving and processing sensor signals, and the signal converter transmits the sensor signals to a PLC (programmable logic controller). The PLC sends the received sensor signal to the MCGS system; the input end of the isolation circuit is connected with the alternating current side of the power supply, and the output end of the isolation circuit is connected with the input end of the signal conditioning circuit. The surge protection circuit is provided with a TVS diode and an RC filter, high-frequency noise in signals can be filtered out firstly, the signals are made to be purer, after passing through the RC filter, the signals enter the TVS diode, at the moment, most noise in the signals is filtered out, the TVS diode responds rapidly when the voltage exceeds the threshold value of the TVS diode, and the voltage is clamped within a safe range. Because most of high-frequency noise is removed by the RC filter, the false triggering probability of the TVS diode is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of integrated control circuits, in particular to an integrated control system for an air compressor station. Background Art

[0002] The integrated control of the air compressor station is mainly used for real-time monitoring and control of the operating status of the air compressor and its auxiliary equipment. The operating parameters of the air compressor, such as pressure, temperature, flow and vibration, are collected through sensors, and these signals are processed through signal conditioning circuits to ensure the accuracy and stability of the signals.

[0003] In the existing integrated control circuit of the air compressor station, the signal is severely attenuated during long-distance transmission, which affects the integrity and accuracy of the signal. In view of this, an integrated control system for the air compressor station is provided. Utility Model Content

[0004] The main purpose of the utility model is to provide an integrated control system for an air compressor station to solve the problem in the related art that the signal is severely attenuated during long-distance transmission, affecting the integrity and accuracy of the signal.

[0005] To achieve the above objectives, according to one aspect of the present invention, an integrated control system for an air compressor station is provided, comprising a signal converter, wherein an input end of the signal converter is connected to a signal conditioning circuit, wherein the signal conditioning circuit is used to receive and process sensor signals, and the signal converter transmits the sensor signals to a PLC, which transmits the received sensor signals to an MCGS system; and further comprising:

[0006] An isolation circuit, wherein the input end of the isolation circuit is connected to the AC side of the power supply, and the output end of the isolation circuit is connected to the input end of the signal conditioning circuit;

[0007] Wherein, the PLC at least includes:

[0008] IO interface module: The IO interface module is used to transmit the device signal to the PLC and send the PLC output signal to the actuator;

[0009] A communication port is connected to a surge protection circuit.

[0010] Further, the signal conditioning circuit includes a non-inverting amplifier, an RC filter, a voltage regulator, a +12V DC power supply, an analog-to-digital converter, and a photocoupler;

[0011] Specifically, the output end of the sensor signal is connected to the input end of the non-inverting amplifier, the output end of the non-inverting amplifier is connected to the input end of the RC filter, and the non-inverting amplifier is powered by a +12V DC power supply, the +12V DC power supply is connected to the Vcc pin of the RC filter, GND is connected to the ground pin of the RC filter, the output end of the RC filter is connected to the input end of the photoelectric coupler, the output end of the photoelectric coupler is connected to the input end of the analog-to-digital converter, and at the same time, the photoelectric coupler is powered by a +12V DC power supply, the +12V DC power supply is connected to the positive pole of the LED side of the photoelectric coupler, GND is connected to the negative pole of the LED side of the photoelectric coupler, the output end of the analog-to-digital converter is connected to the input end of the signal converter, and the output end of the signal converter is connected to the PLC through the RS-485 bus based on the Modbus RTU protocol;

[0012] At the same time, the +12V DC power supply is connected to the input terminal of the voltage regulator, the voltage regulator outputs a 5V power supply, and the 5V power supply is connected to the Vcc pin of the analog-to-digital converter, and the GND pin of the analog-to-digital converter is grounded.

[0013] Furthermore, the isolation circuit specifically includes an isolation transformer;

[0014] The primary side of the isolation transformer is connected to the AC side of the power supply, and the secondary side of the isolation transformer is connected to the input end of the signal conditioning circuit.

[0015] The isolation transformer prevents high voltage or fault current on the power supply side from being directly transmitted to the control system through electrical isolation between its primary and secondary sides. It ensures that the signal conditioning circuit and other circuits receive a relatively clean power supply that is isolated from the power grid.

[0016] Isolation transformers can reduce the impact of electromagnetic interference (EMI) and radio frequency interference (RFI) in the power grid on the control system, thereby improving the stability and reliability of the system.

[0017] Furthermore, the surge protection circuit comprises at least an RC filter, a phototransistor coupler and a surge protector;

[0018] The communication port is based on the Modbus RTU protocol and is connected to the RC filter input via the RS-485 bus. The RC filter output is connected to a surge protector. The surge protector output is connected to a phototransistor coupler. The phototransistor coupler output is connected to the communication port input. The surge protector is grounded.

[0019] At the same time, a TVS diode is set between the communication port and the filter. The TVS diode is connected in parallel to the positive and negative lines of the RS-485 bus to quickly respond to transient voltages.

[0020] Furthermore, the PLC further comprises a CPU input port and a CPU output port;

[0021] Wherein, the CPU input port is connected to the output end of the signal converter;

[0022] The CPU output port is connected to the input port of the MCGS system.

[0023] Furthermore, the IO interface module includes a DI port, a DO port, an AI port and an AO port.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. In the integrated control system of the air compressor station, an isolation circuit is used to prevent high voltage or fault current on the power supply side from being directly transmitted into the control system. At the same time, a signal conditioning circuit is set on the input side of the signal converter;

[0026] The signal conditioning circuit uses a non-inverting amplifier and an RC filter to optimize signal quality. The RC filter removes high-frequency noise from the sensor signal, making the signal purer. The non-inverting amplifier then amplifies the filtered signal to ensure sufficient signal strength for subsequent processing.

[0027] And provide stable DC power to different parts of the signal conditioning circuit through the +12V DC power supply.

[0028] 2. In the integrated control system of the air compressor station, a TVS diode is installed in the surge protection circuit. The RC filter can first filter out high-frequency noise in the signal, making the signal purer. After passing through the RC filter, the signal enters the TVS diode, at which point most of the noise in the signal has been filtered out. The TVS diode responds quickly when the voltage exceeds its threshold, clamping the voltage within a safe range. Because the RC filter has removed most of the high-frequency noise, the probability of false triggering of the TVS diode is reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a schematic diagram of circuit module connections in a preferred embodiment of the present invention.

[0030] Illustration:

[0031] 1. Signal converter;

[0032] 2. Isolation circuit;

[0033] 3. Signal conditioning circuit;

[0034] 4. Surge protection circuit. DETAILED DESCRIPTION

[0035] In order to further illustrate the technical means and effects adopted by the present invention to achieve the predetermined purpose of the utility model, the following is a detailed description of the specific implementation method, structure, characteristics and effects of the present invention in combination with the accompanying drawings and preferred embodiments.

[0036] Example 1

[0037] See also Figure 1 As shown, the purpose of this embodiment is to provide an integrated control system for an air compressor station, including a signal converter 1, wherein the input end of the signal converter 1 is connected to a signal conditioning circuit 3, the signal conditioning circuit 3 is used to receive and process sensor signals, and the signal converter 1 transmits the sensor signals to the PLC, and the PLC sends the received sensor signals to the MCGS system through the RS-485 bus based on the Modbus RTU protocol; and also includes:

[0038] Isolation circuit 2, where the input end of isolation circuit 2 is connected to the AC side of the power supply, and the output end of isolation circuit 2 is connected to the input end of signal conditioning circuit 3;

[0039] Wherein, the PLC at least includes:

[0040] IO interface module: The IO interface module is used to transmit the device signal to the PLC and send the PLC output signal to the actuator;

[0041] The communication port is connected to a surge protection circuit 4 for protecting the communication port from the influence of surges.

[0042] Signal converter 1 is used to convert the original signal of the sensor into a form suitable for digital processing, and further perform data format conversion, signal enhancement, isolation or other necessary conversion steps to ensure that the signal can be correctly transmitted to the PLC and maintain consistency and integrity throughout the system;

[0043] The main function of the analog-to-digital converter (ADC) is to convert continuously changing analog signals into discrete digital signals for processing by digital processors (such as PLCs).

[0044] In this embodiment, the signal conditioning circuit 3 includes a non-inverting amplifier, an RC filter, a voltage regulator, a +12VDC power supply, an analog-to-digital converter, and a photocoupler;

[0045] Specifically, the output end of the sensor signal is connected to the input end of the non-inverting amplifier, the output end of the non-inverting amplifier is connected to the input end of the RC filter, and the non-inverting amplifier is powered by a +12V DC power supply, the +12V DC power supply is connected to the Vcc pin of the RC filter, GND is connected to the ground pin of the RC filter, the output end of the RC filter is connected to the input end of the photoelectric coupler, the output end of the photoelectric coupler is connected to the input end of the analog-to-digital converter, and at the same time, the photoelectric coupler is powered by a +12V DC power supply, the +12V DC power supply is connected to the positive pole of the LED side of the photoelectric coupler, GND is connected to the negative pole of the LED side of the photoelectric coupler, the output end of the analog-to-digital converter is connected to the input end of the signal converter 1, and the output end of the signal converter 1 is connected to the PLC through the RS-485 bus based on the Modbus RTU protocol;

[0046] At the same time, the +12V DC power supply is connected to the input terminal of the voltage regulator, the voltage regulator outputs a 5V power supply, and the 5V power supply is connected to the Vcc pin of the analog-to-digital converter, and the GND pin of the analog-to-digital converter is grounded.

[0047] The cutoff frequency of an RC filter determines the noise frequencies it can filter out. The gain of a non-inverting amplifier affects the overall signal strength. By properly selecting the RC filter's RC value and the gain of the non-inverting amplifier, the signal bandwidth can be optimized, ensuring that only signals within the desired frequency range are amplified and transmitted. Furthermore, the RC filter reduces noise components, while the non-inverting amplifier enhances the useful components of the signal. The combination of the two significantly improves the signal-to-noise ratio, making the signal clearer and more reliable.

[0048] The sensor signal is first sent to a non-inverting amplifier for amplification and then filtered through an RC filter. Even if the sensor signal is weak, it can be enhanced by the non-inverting amplifier and then the noise is removed by the RC filter to ensure that the filtered signal still has sufficient strength.

[0049] Specifically, the photosensitive output side of the optocoupler:

[0050] The base acts as the input of the optocoupler and is connected to the output of the RC filter;

[0051] The emitter is connected to ground (GND);

[0052] The collector is connected to the 5V power supply output by the voltage regulator and connected to the input of the analog-to-digital converter through a current-limiting resistor;

[0053] LED side of the optocoupler:

[0054] The positive electrode is connected to the output of the RC filter;

[0055] The negative terminal is connected to ground (GND);

[0056] Furthermore, the +12V DC power supply is used to power the signal conditioning circuit 3;

[0057] Specifically, the +12V DC power supply is used to power the non-inverting amplifier, optocoupler, and voltage regulator respectively;

[0058] Sensors include but are not limited to pressure sensors, temperature sensors, flow sensors, vibration sensors, etc. The signal conditioning circuit 3 needs to ensure the quality of the signal while protecting the subsequent control system (such as PLC) from the influence of the external environment.

[0059] Specifically, the isolation circuit 2 specifically includes an isolation transformer;

[0060] The primary side of the isolation transformer is connected to the AC side of the power supply, and the secondary side of the isolation transformer is connected to the input end of the signal conditioning circuit 3 .

[0061] The isolation transformer prevents high voltage or fault current on the power supply side from being directly transmitted to the control system through electrical isolation between its primary and secondary sides. It ensures that the signal conditioning circuit 3 and other circuits receive a relatively clean power supply that is isolated from the power grid.

[0062] Isolation transformers can reduce the impact of electromagnetic interference (EMI) and radio frequency interference (RFI) in the power grid on the control system, thereby improving the stability and reliability of the system.

[0063] In this embodiment, the surge protection circuit 4 includes at least an RC filter, a phototransistor coupler and a surge protector;

[0064] The communication port is based on the Modbus RTU protocol and is connected to the RC filter input via the RS-485 bus. The RC filter output is connected to a surge protector. The surge protector output is connected to a phototransistor coupler. The phototransistor coupler output is connected to the communication port input. The surge protector is grounded.

[0065] The phototransistor coupler provides electrical isolation to prevent the transient voltage generated by the surge protector from being directly transmitted to the downstream circuit. Even if the surge protector is activated, the photocoupler can ensure the safety of the downstream circuit.

[0066] At the same time, a TVS diode is set between the communication port and the filter. The TVS diode is connected in parallel to the positive and negative lines of the RS-485 bus to quickly respond to transient voltages.

[0067] Among them, the main function of the surge protection circuit in the integrated control system of the air compressor station is to protect sensitive electronic equipment (such as PLC, communication modules, etc.) from damage caused by surges (sudden increase in voltage or current) on the power line or signal line.

[0068] An RC filter first removes high-frequency noise from the signal, making it purer. After passing through the RC filter, the signal enters the surge protector. The surge protector activates when the voltage exceeds a set threshold, absorbing or diverting the surge energy. Positioning the RC filter before the surge protector reduces noise entering the device, thereby minimizing false trips. Furthermore, the surge protector prevents signal distortion or damage caused by surges.

[0069] As a supplementary protection measure, TVS diodes can work together with surge protectors to ensure the reliability of communication ports. Even if the surge protector fails to fully absorb the surge, the TVS diode can provide additional protection.

[0070] Phototransistor couplers provide electrical isolation, preventing surges from propagating through signal lines to downstream circuits. Even if a TVS diode fails to fully absorb the surge, the photocoupler can further isolate downstream circuits, ensuring their safety. Photocouplers transmit signals via light, making them immune to electromagnetic interference and ensuring signal integrity during transmission.

[0071] Furthermore, a surge protector absorbs surges when the voltage exceeds a threshold, while a TVS diode quickly responds when the voltage reaches its threshold, clamping the voltage within a safe range. Combining the two provides more comprehensive protection; surge protectors are typically used to absorb larger surge energy, while TVS diodes quickly respond to smaller transient voltage spikes. The two complement each other, ensuring effective protection under varying surge intensities.

[0072] In this embodiment, the PLC further includes a CPU input port and a CPU output port;

[0073] Wherein, the CPU input port is connected to the output end of the signal converter 1;

[0074] The CPU output port is connected to the input port of the MCGS system, where the MCGS system is a human-machine interface (HMI) used to build an industrial automation control system, that is, the operator can monitor and control the production process through this interface.

[0075] In this embodiment, the IO interface module includes a DI port, a DO port, an AI port and an AO port;

[0076] Specifically, the DI port is a digital input port used to receive switch signals from external devices and monitor the status of external devices, such as whether a button is pressed or whether a sensor detects a specific condition (such as door open / close status, proximity sensor detecting an object, etc.);

[0077] The DO port is a digital output port used to send switch signals to external devices to control the actions of external devices, such as starting a motor, opening a solenoid valve, etc.

[0078] The AI ​​port is an analog input port used to receive continuously changing electrical signals (usually voltage or current signals) from sensors or transmitters to measure changes in physical quantities such as temperature, pressure, speed, etc.

[0079] The AO port is an analog output port, which is used to send continuously changing electrical signals to external devices to control devices that need to be adjusted, such as adjusting the opening of a valve, setting the speed of a frequency converter, etc.

[0080] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to equivalent embodiments using the technical contents disclosed above without departing from the scope of the technical solution of the present invention. However, any brief modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. The integrated control system of the air compressor station is characterized by: The system comprises a signal converter (1), wherein the input end of the signal converter (1) is connected to a signal conditioning circuit (3), wherein the signal conditioning circuit (3) is used to receive and process sensor signals, wherein the signal converter (1) transmits the sensor signals to a PLC, and the PLC transmits the received sensor signals to an MCGS system; and further comprises: An isolation circuit (2), wherein an input end of the isolation circuit (2) is connected to the AC side of a power supply, and an output end of the isolation circuit (2) is connected to an input end of a signal conditioning circuit (3); Wherein, the PLC at least includes: IO interface module: The IO interface module is used to transmit the device signal to the PLC and send the PLC output signal to the actuator; A communication port, wherein the communication port is connected to a surge protection circuit (4).

2. The integrated control system of the air compressor station according to claim 1 is characterized in that: The signal conditioning circuit (3) includes a non-inverting amplifier, an RC filter, a voltage regulator, a +12V DC power supply, an analog-to-digital converter and a photoelectric coupler; Specifically, the output end of the sensor signal is connected to the input end of the non-inverting amplifier, the output end of the non-inverting amplifier is connected to the input end of the RC filter, and the non-inverting amplifier is powered by a +12V DC power supply, the output end of the RC filter is connected to the input end of the photoelectric coupler, the output end of the photoelectric coupler is connected to the input end of the analog-to-digital converter, the output end of the analog-to-digital converter is connected to the input end of the signal converter (1), and the output end of the signal converter (1) is connected to the PLC based on the Modbus RTU protocol and through the RS-485 bus; At the same time, the +12V DC power supply is connected to the input terminal of the voltage regulator, the voltage regulator outputs a 5V power supply, and the 5V power supply is connected to the Vcc pin of the analog-to-digital converter, and the GND pin of the analog-to-digital converter is grounded.

3. The integrated control system of the air compressor station according to claim 1, characterized in that: The isolation circuit (2) specifically includes an isolation transformer; The primary side of the isolation transformer is connected to the AC side of the power supply, and the secondary side of the isolation transformer is connected to the input end of the signal conditioning circuit (3).

4. The integrated control system of the air compressor station according to claim 1, characterized in that: The surge protection circuit (4) comprises at least an RC filter, a phototransistor coupler and a surge protector; The communication port is based on the Modbus RTU protocol and is connected to the RC filter input via the RS-485 bus. The RC filter output is connected to a surge protector. The surge protector output is connected to a phototransistor coupler. The phototransistor coupler output is connected to the communication port input. The surge protector is grounded. At the same time, a TVS diode is set between the communication port and the filter. The TVS diode is connected in parallel to the positive and negative lines of the RS-485 bus to quickly respond to transient voltages.

5. The integrated control system of the air compressor station according to claim 1, characterized in that: The PLC also includes a CPU input port and a CPU output port; Wherein, the CPU input port is connected to the output end of the signal converter (1); The CPU output port is connected to the input port of the MCGS system.

6. The integrated control system of the air compressor station according to claim 1, characterized in that: The IO interface module includes a DI port, a DO port, an AI port and an AO port.

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