Box-type substation communication management machine

Abstract

The utility model belongs to the technical field of electric power complete equipment, and relates to a box-type substation communication technology. The communication management machine is provided for solving the problem that remote communication monitoring and management cannot be achieved due to the fact that most of existing box-type substations are in a traditional power distribution equipment scheme. The system has the functions of local communication, data acquisition and processing, protocol conversion, remote communication, remote upgrading and the like. The local communication module has eight independent serial ports and an RS485 communication function, and can safely isolate and collect data; a plurality of analysis protocols are built in the protocol conversion module, and data formats can be converted; the remote communication module comprises an Ethernet port used for uploading data and configuring parameters; the real-time clock RTC module provides accurate time; and a FLASH storage module and a program downloading and error printing interface are also arranged. Through the functions, remote mastering, processing, uploading and management of operation data of the box-type substation can be realized, faults can be early warned in advance, and the maintenance workload is reduced.

Description

Technical Field

[0001] This utility model relates to the field of power complete equipment technology, specifically to communication technology for prefabricated substations. Background Technology

[0002] (a) Existing technology

[0003] In current power systems, most prefabricated substations employ relatively traditional power distribution equipment schemes. These traditional schemes often focus on basic power distribution and conversion functions. From a hardware perspective, the main equipment within a prefabricated substation includes transformers, high- and low-voltage switchgear, etc., which are typically not designed and installed with sufficient consideration for communication integration. On the software side, their control systems are relatively simple, only capable of local manual or simple automated operations, such as local switching operations and basic overload and short-circuit protection. Their communication interfaces are limited, generally only possessing simple interfaces for local display, unable to achieve effective connection with external systems. This situation results in extremely weak communication capabilities between internal equipment and with external monitoring systems within the prefabricated substation, severely limiting comprehensive control and management of the substation's operational status.

[0004] (II) Technological Development

[0005] With the continuous advancement of intelligent and information-based processes in power systems, remote monitoring and management of power equipment has become an important direction for industry development. In the field of large substations, smart grid technology has been widely applied. For example, by installing advanced sensors and smart meters, parameters such as voltage, current, and power factor within the substation can be collected with high precision and in real time. Simultaneously, with the help of advanced communication methods such as fiber optic and wireless communication, this data can be quickly transmitted to a remote monitoring center. At the remote monitoring center, big data analysis and artificial intelligence algorithms can be used to accurately assess the substation's operating status, predict equipment failures in advance, and achieve remote operation and control. However, in the field of prefabricated substations, despite the same demand for intelligent management, due to their inherent characteristics (such as dispersed distribution and relatively small single-station capacity), the application of technology lags significantly behind that of large substations.

[0006] (III) Current Pain Points and Difficulties

[0007] 1. Lack of remote monitoring capabilities

[0008] 1. Prefabricated substations are often widely distributed and dispersed, possibly located in various corners of cities, remote suburbs, or even mountainous areas. Traditional local monitoring methods rely on manual on-site inspections, requiring maintenance personnel to periodically visit each site for checks. This not only consumes significant manpower, resources, and time, but also, due to the limitations of the inspection cycle, cannot provide real-time monitoring of the substation's operational status. If a prefabricated substation malfunctions, such as overheating or short circuits, maintenance personnel may struggle to detect it promptly, potentially leading to power outages, affecting the normal electricity use of residents and businesses, and even causing production accidents and economic losses.

[0009] 2. Data processing and management difficulties

[0010] 1. Existing prefabricated substations lack a comprehensive data acquisition and processing mechanism. During operation, although the equipment generates a large amount of valuable data, such as real-time operating parameters like voltage, current, and power, the lack of effective acquisition methods prevents the comprehensive and accurate acquisition of this data. Even when some data is acquired, the absence of a professional data processing system hinders in-depth analysis and makes it difficult to identify potential equipment malfunctions. Furthermore, there are numerous problems with the storage and management of the collected data. Data may be scattered across various local devices, lacking a unified data management platform, increasing the risk of data loss and corruption, and hindering long-term maintenance and management of the equipment by power companies.

[0011] 3. Poor protocol compatibility

[0012] 1. Prefabricated substations typically integrate equipment from multiple manufacturers, each often employing its own communication protocols during design and production. For example, transformers might use a protocol based on a specific industry standard, while switchgear might use a different manufacturer-defined protocol. Under current technological conditions, effective data exchange and collaborative operation between these different protocols are difficult. When unified management and monitoring of the entire prefabricated substation are required, this protocol incompatibility leads to data transmission obstacles, limiting the overall functionality of the prefabricated substation and increasing the difficulty of system integration and operation and maintenance. Utility Model Content

[0013] (I) Utility Model Principle

[0014] This utility model's prefabricated substation communication management unit is mainly based on modern electronic technology, communication technology, and data processing technology. It integrates multiple functional modules to achieve efficient management of the prefabricated substation.

[0015] Local communication module

[0016] This module features eight independent serial ports and supports RS485 communication. These interfaces allow connection to various devices within the prefabricated substation, such as transformer monitoring devices and switchgear status monitors. During data acquisition, secure isolation technology is employed to ensure no interference occurs when collecting data from different devices, guaranteeing data accuracy and stability. For example, when acquiring transformer oil temperature data and switchgear open / closed status data, these data can be obtained independently and accurately.

[0017] Data acquisition and processing module

[0018] This module is responsible for the centralized processing of data acquired from the local communication module. It can perform quantization, filtering, and calibration operations on various analog quantities (such as voltage and current) and digital quantities (such as device status signals). Taking voltage data acquisition as an example, the raw voltage signal is filtered to remove noise interference, and then quantized and calibrated to convert it into an accurate digital signal that can be used for subsequent analysis and processing.

[0019] Protocol conversion module

[0020] Built-in multiple data parsing protocols enable the identification and conversion of data in different formats from various devices. Since equipment within a prefabricated substation may originate from different manufacturers and employ different communication protocols, this module can unify these heterogeneous data formats into a standard format that facilitates management and transmission. For example, it can convert the data from devices using the Modbus and Profibus protocols into a unified internal data format.

[0021] Remote communication module

[0022] This module includes an Ethernet port and uses network protocols such as TCP / IP to upload processed and converted data to the remote monitoring center. Simultaneously, it can receive configuration parameters and control commands from the remote monitoring center and accurately transmit them to local devices. For example, the remote monitoring center can use this module to send remote operation commands to the switchgear within the prefabricated substation, achieving remote control.

[0023] Real-time clock (RTC) module

[0024] It provides a precise time reference for the entire system. During data acquisition and recording, it can accurately timestamp each data point. For example, when recording the time of equipment failure, it can be accurate to the second or even millisecond, facilitating subsequent accurate analysis and tracing of the failure process.

[0025] FLASH storage module

[0026] It is used to store important information such as collected data, system configuration parameters, and operation logs. When network failures or other reasons prevent data from being uploaded to the remote monitoring center in a timely manner, the data can be temporarily stored in FLASH and uploaded again after the network is restored, ensuring that the data is not lost.

[0027] Program download and error printing interface

[0028] This interface facilitates program updates and upgrades for the communication management unit. Furthermore, in the event of a system malfunction, it prints detailed error information, enabling technicians to quickly locate and resolve problems. For example, when data transmission anomalies are detected, the interface can retrieve relevant error codes to analyze whether the issue stems from a software program problem or a hardware failure.

[0029] (ii) Beneficial effects

[0030] Realize remote monitoring and management

[0031] The prefabricated substation communication management unit, through a remote communication module, can upload real-time operational data from the substation to a remote monitoring center. This allows maintenance personnel to gain a comprehensive understanding of the substation's operational status, such as real-time voltage, current, and equipment operating temperature, without needing to be on-site. For prefabricated substations located in remote areas, this significantly reduces the workload of maintenance personnel during inspections. For example, in a city's power supply network, there may be hundreds of prefabricated substations distributed throughout the city. Through this communication management unit, maintenance personnel can simultaneously monitor these substations from the monitoring center, promptly identifying and addressing any anomalies.

[0032] Improve fault early warning and handling capabilities

[0033] With the help of data acquisition and processing modules and a real-time clock (RTC) module, the acquired data can be analyzed in real time. By establishing a reasonable fault early warning model, warning signals can be issued in advance when potential fault signs appear in the equipment (such as a gradual increase in equipment temperature, abnormal current fluctuations, etc.). This helps maintenance personnel take measures before a fault occurs, avoiding its occurrence or reducing its impact. For example, when the transformer oil temperature rises faster than the normal threshold, a timely warning can be issued, allowing maintenance personnel to schedule inspections and maintenance in advance to prevent transformer overheating and damage.

[0034] Enhanced data processing and compatibility

[0035] The protocol conversion module resolves the incompatibility issue of communication protocols between different devices within a prefabricated substation. By converting various heterogeneous data into a unified format, it not only facilitates unified management of equipment within the substation but also promotes integration with external systems. Simultaneously, the data acquisition and processing module can efficiently process large amounts of data, providing strong support for data analysis and decision-making in power companies. For example, power companies can optimize grid operation strategies and improve power supply reliability by analyzing long-term operating data from multiple prefabricated substations.

[0036] Reduce operation and maintenance costs

[0037] Remote monitoring and fault early warning systems have reduced the frequency of on-site inspections and labor costs. Furthermore, accurate monitoring of equipment operating status allows for the rational planning of maintenance and replacement schedules, avoiding unnecessary repairs and replacements and further reducing operation and maintenance costs. For example, previously, weekly on-site inspections of prefabricated substations were required; now, based on remote monitoring data, the inspection cycle can be extended to once a month or even longer, while also reducing maintenance costs due to unforeseen failures.

[0038] Facilitates system upgrades and maintenance

[0039] The program download and error printing interfaces make software upgrades and troubleshooting of the communication management unit much more convenient. Power companies can upgrade the communication management unit's software in a timely manner, adding new functions or optimizing existing functions, based on technological advancements and actual needs. When system failures occur, problems can be quickly located and resolved, reducing system downtime. For example, when it is necessary to add support for new equipment, the software can be easily updated through the program download interface, enabling the communication management unit to effectively communicate and manage the new equipment. Attached Figure Description

[0040] Figure 1 Overall design scheme;

[0041] Figure 2 RS485 local data acquisition and communication module;

[0042] Figure 3 Data storage;

[0043] Figure 4 Real-time clock (RTC)

[0044] Figure 5 Schematic diagram of communication management structure for prefabricated substation;

[0045] Figure 6 : Schematic diagram of a node with 8 independent serial ports and RS485 communication function;

[0046] Figure 7The conversion module includes schematic diagrams of various parsing protocols.

[0047] Figure 8 : Schematic diagram of the Ethernet port of the remote communication module;

[0048] Figure 9 : Schematic diagram of the remote upgrade module of the communication management unit for prefabricated substations;

[0049] Figure 10 Timing diagram of the real-time clock (RTC) module of the prefabricated substation communication management unit;

[0050] Figure 11 Schematic diagram of the Real-Time Clock (RTC) module component of the prefabricated substation communication management unit;

[0051] Figure 12 : Schematic diagram of FLASH storage for communication management unit in prefabricated substation

[0052] Figure 13 Schematic diagram of hardware self-transmit / receive control circuit. Detailed Implementation

[0053] Implementation method one, combined with implementation method 1 and appendix Figure 1 , Figure 2 , Figure 3 , Figure 4 The details are as follows:

[0054] 1. Overall structure and functional implementation of the prefabricated substation communication management unit

[0055] The prefabricated substation communication management unit, as a key innovation in the field of power complete equipment technology, provides a comprehensive solution to overcome the limitations of traditional prefabricated substations in communication and management. The following will be discussed in conjunction with the attached... Figures 1 to 4 The implementation method 1 is described in depth and detail, fully demonstrating its circuit function and the ingenuity of the collaborative work of each module.

[0056] 1.1 Overall Design Scheme (Appendix) Figure 1 )

[0057] The prefabricated substation communication management unit is a highly integrated intelligent device, its core architecture constructed from multiple functional modules. (See attached image) Figure 1 As shown, the power module acts as the energy source for the entire system, providing a stable power supply to each functional module and ensuring its normal operation. The MCU processor, on the other hand, serves as the brain of the system, responsible for coordinating and controlling the data flow, instruction execution, and logical operations between the modules.

[0058] The local communication module, serving as the front-end interface for data acquisition, establishes a tight data connection with various devices within the prefabricated substation through its at least eight independent serial ports and RS485 communication capabilities. Following this, the data acquisition and processing module performs in-depth processing and preprocessing on the data acquired by the local communication module. The protocol conversion module acts as a data translator, uniformly converting data of different formats into a protocol format suitable for remote transmission, enabling the subsequent remote communication module to successfully upload data to a remote or local area network management platform.

[0059] The Real-Time Clock (RTC) module injects a precise time dimension into the entire system, providing an accurate time reference for data acquisition and recording. The FLASH storage module acts as a large-capacity data warehouse, storing various critical data, including remote upgrade data, acquired data, system configuration parameters, and operational logs. The program download and error printing interfaces provide convenient channels for system software maintenance and fault diagnosis, facilitating software upgrades and rapid troubleshooting when system failures occur.

[0060] Through carefully designed circuit connections and communication protocols, the various modules work together to form an efficient, stable, and intelligent data processing and communication system, laying a solid foundation for remote monitoring, management, and intelligent operation and maintenance of prefabricated substations.

[0061] 1.1.1 Local communication module and data acquisition and processing module (attached) Figure 2 )

[0062] 1.1.1.1 Local Communication Module

[0063] The core of the local communication module lies in its at least eight independent serial ports and powerful RS485 communication capabilities. (See attached...) Figure 2 The circuit structure and working principle can be analyzed in detail. Taking one of the serial ports, such as serial port 1, as an example, its circuit connection involves the coordinated operation of multiple electronic components. Resistors such as R19 and R23 play the role of current limiting and impedance matching in the circuit, ensuring the stability of signal transmission. MCU_RX1 and MCU_TX1 are the receive and transmit pins of the microcontroller (MCU), respectively, and they interact with the serial communication chip (such as U15) for data exchange.

[0064] When communicating with equipment within the prefabricated substation, taking the temperature control device of the transformer connected to serial port 1 as an example, the temperature data signal output by the temperature control device is transmitted to the serial port 1 circuit via the RS485 bus. 485A1 and 485B1 are the differential signal pins for RS485 communication. The signal is electrically isolated by diodes such as D10 and D14 to prevent external interference signals from entering the system and to protect the internal circuitry from external overvoltage surges. Resistors such as R127 and R123 form a terminating resistor network to ensure the quality of signal transmission on the bus and reduce reflections and signal distortion.

[0065] Optocouplers (such as Q7) play a crucial isolating role in the circuit, completely isolating the communication line from the MCU-side circuitry, making data transmission safer and more reliable. Even in complex electromagnetic environments, such as those in a prefabricated substation where numerous electrical devices generate electromagnetic interference, this isolation effectively ensures data accuracy and stability. For example, when high-voltage side equipment generates strong electromagnetic pulses during switching operations, optocoupler isolation prevents these interference signals from affecting data acquisition and transmission, ensuring that serial port 1 can accurately acquire temperature data from the transformer temperature control device.

[0066] 1.1.1.2 Data Acquisition and Processing Module

[0067] The data acquisition and processing module's circuitry revolves around processing various types of input data. For analog inputs, such as voltage signals, the signal is first sampled by the front-end sampling circuit. Capacitors (such as C32) and resistors (such as R124 and R125) in the sampling circuit form a filtering network to perform preliminary filtering of the input voltage signal, removing high-frequency noise interference. Then, the signal enters the analog-to-digital converter (ADC) circuit for quantization. The ADC converts continuously changing analog voltage values ​​into discrete digital quantities; its conversion accuracy and speed depend on the performance parameters of the ADC chip.

[0068] In terms of digital signal processing, such as equipment status signals, these signals are directly input to the MCU for processing via corresponding input interfaces. The MCU performs logical judgments and status monitoring on the acquired digital signals. Taking the status monitoring of high-voltage switchgear as an example, when the switchgear's switching status changes, the corresponding status signal enters the MCU through the digital input interface of the data acquisition and processing module. The MCU can quickly detect this change and record the time and status information of the change.

[0069] Meanwhile, the data acquisition and processing module also has a calibration function. In the calibration circuit, the acquired analog data is precisely calibrated using a preset reference voltage source (such as U11) and calibration algorithm to ensure data accuracy. For example, during long-term operation, factors such as temperature changes and component aging may cause deviations in the voltage acquisition values. The calibration function can correct these deviations in real time, ensuring that the acquired data always accurately reflects the actual operating status of the equipment in the prefabricated substation.

[0070] 1.1.2 Protocol Conversion Module (The internal workings of the protocol conversion are not shown in detail in the attached diagram, but its function can be explained.)

[0071] Although the internal circuitry of the protocol conversion module is not shown in detail in the accompanying diagram, its functional importance cannot be ignored. When data from different protocols is transmitted from the data acquisition and processing module, the protocol conversion module performs data format conversion based on various built-in parsing protocols (such as MODUBS, DLT645, MQTT, ICE104, etc.).

[0072] Assuming the transformer monitoring data collected from the local communication module uses the MODBUS protocol, the protocol conversion module first identifies the protocol format. Then, according to pre-set conversion rules, it parses the MODBUS protocol data structure and extracts key data information, such as transformer oil temperature, winding temperature, and load current. Next, this data is repackaged according to an internally unified protocol format so that the subsequent remote communication module can accurately upload the data to the management platform.

[0073] Similarly, the protocol conversion module can perform the same conversion operation for low-voltage side smart meter data using the DLT645 protocol. This protocol conversion function effectively solves the problem of protocol incompatibility caused by equipment from different manufacturers within the prefabricated substation, realizing unified management of equipment data within the substation and seamless connection for remote transmission, greatly improving the overall intelligent management level and data interaction efficiency of the prefabricated substation.

[0074] 1.1.3 Real-time Clock (RTC) Module (with attachment) Figure 4 )

[0075] The circuit design of the Real-Time Clock (RTC) module revolves around providing an accurate time base. (See attached...) Figure 4 As shown, the crystal oscillator (such as U9) serves as the clock source, and its stable oscillation frequency provides a precise timing basis for the RTC module. Capacitors C19, C20, C21, etc., together with the crystal oscillator, constitute the oscillation circuit, ensuring the stability and accuracy of the oscillation frequency.

[0076] When the main power supply is normal, the +3.3V power supply provides the operating voltage for the RTC module and simultaneously charges the batteries (such as D8 and D9). When the main power supply fails, the batteries immediately take over the power supply task, ensuring the RTC module continues to operate and that time information is not lost. I2C_SCLI and I2C_SDAI are I2C bus interfaces used for communication between the RTC module and the MCU. The MCU reads the real-time time information provided by the RTC module through the I2C bus and adds an accurate timestamp to each data point during data acquisition and recording.

[0077] For example, during the operation of a prefabricated substation, when equipment failure or abnormal events occur, the data acquisition and processing module records relevant data (such as sudden changes in voltage and current, changes in equipment status, etc.) while simultaneously obtaining precise time information from the real-time clock (RTC) module, closely linking the data with time. This is crucial for subsequent fault analysis and accident tracing. Technicians can accurately reconstruct the event process based on the time sequence and data changes, thereby quickly locating the cause of the fault and taking effective corrective measures.

[0078] 1.1.4 FLASH storage module (attached) Figure 3 )

[0079] The circuit diagram of the FLASH storage module is shown in the attached figure. Figure 3 As shown, its core memory chip (such as U3) communicates with the MCU via the SPI bus. SPI_CLK is the clock signal pin, used for synchronous data transmission; SPI_MOSI is the data input pin, through which the MCU transmits the data to be stored to the FLASH chip; SPI_MISO is the data output pin, through which data is transmitted back to the MCU when reading data stored in the FLASH. CS# is the chip select signal pin, used to select a specific FLASH chip for operation.

[0080] During data storage, when the data acquisition and processing module prepares to store various processed data (such as operating parameters, event logs, system configurations, etc.), the MCU first sends a write command to the FLASH storage module via the SPI bus, transferring the data byte by byte to the FLASH chip. The internal storage units of the FLASH chip store the data according to certain address rules. When data needs to be read, the MCU sends a read command, and the FLASH chip returns the corresponding data to the MCU via the SPI bus based on the address information in the command.

[0081] For example, in the daily operation of a prefabricated substation, data such as voltage, current, and power are collected at regular intervals (e.g., every minute). After being processed by the data acquisition and processing module, the data is stored in the FLASH memory module. Simultaneously, system configuration parameters (such as communication baud rate and IP address) and operation logs (such as equipment startup time, software upgrade records, and fault alarm information) are also stored in the FLASH memory. When the remote communication module detects a normal network connection, the MCU reads the data to be uploaded from the FLASH memory module and sends it to the remote management platform via the remote communication module, ensuring timely data upload and effective remote monitoring. Furthermore, when historical data needs to be queried locally or fault diagnosis needs to be performed, technicians can also retrieve the relevant data from the FLASH memory module through the MCU, providing strong support for operation and maintenance work.

[0082] The above detailed explanation of the circuit functions of each main module of the prefabricated substation communication management unit, combined with the appendix... Figures 1 to 4 A thorough analysis reveals how each component works in concert to achieve efficient data collection, precise processing, protocol conversion, accurate time stamping, reliable storage, and stable remote communication for equipment data within the prefabricated substation. This provides comprehensive and multi-layered technical support for the intelligent management and remote monitoring of prefabricated substations.

[0083] Implementation method two, combined with implementation method two and appendix Figure 5 The details are as follows:

[0084] 1. Implementation Method Two

[0085] 1.1 Combining Implementation Method 2 and Appendix Figure 5 Detailed explanation of the remote communication and upgrade functions of the prefabricated substation communication management unit.

[0086] 1.1.1 Remote communication module (attached) Figure 5 )

[0087] The remote communication module plays a crucial role in the communication management unit of the prefabricated substation. (See attached image.) Figure 5As shown, it mainly includes an Ethernet port. This interface utilizes network protocols such as TCP / IP to upload processed data to a remote or local area network (LAN) management platform. For example, in actual operation, various equipment operating data within the prefabricated substation, such as high-voltage side microprocessor protection data, transformer temperature control data, and high and low voltage side meter data, are collected by the local communication module, processed by the data acquisition and processing module, and converted into a unified format by the protocol conversion module. The remote communication module then accurately transmits this data to the remote management platform via the Ethernet port. Simultaneously, this module can also receive configuration parameters and control commands from the remote monitoring center and reliably transmit them to the local equipment. For instance, the remote monitoring center can send remote operation commands to the switchgear within the prefabricated substation according to actual needs, achieving remote control of the equipment. This significantly improves the intelligent management level and operation and maintenance efficiency of the prefabricated substation.

[0088] 1.1.2 Remote Upgrade Module (Attached) Figure 5 )

[0089] The remote upgrade module facilitates software updates and maintenance for the communication management unit of the prefabricated substation. (Combined with the attached...) Figure 5 When an upgrade of the communication management unit is required, the substation communication management unit is first started, and then the network whitelist of the remote upgrade module is checked. If the whitelist is approved, the on-site communication management unit can connect to the remote upgrade server, thereby realizing remote upgrades and maintenance. This function enables power companies to upgrade the software of the communication management unit in a timely manner according to technological developments and actual needs, adding new functions or optimizing existing functions. For example, when the monitoring requirements of the power system change, requiring the communication management unit to support new data acquisition protocols or have stronger data processing capabilities, the software can be easily updated through the remote upgrade module, ensuring that the communication management unit always maintains good performance and adapts to the ever-evolving power monitoring needs, reducing the difficulty and cost of on-site maintenance.

[0090] Implementation method three, combined with implementation method three and appendix Figure 6 The details are as follows:

[0091] 1. Implementation Method Three

[0092] 1.1 Combining Implementation Method 3 and Appendix Figure 6 A detailed analysis of the protocol conversion module is provided.

[0093] 1.1.1 Protocol Conversion Module (Appendix) Figure 6 )

[0094] The protocol conversion module is a key component of the prefabricated substation communication management unit, enabling unified data management and remote transmission. (See attached...) Figure 6It is known that it has multiple built-in parsing protocols, such as MODUBS, DLT645, MQTT, and ICE104. In the actual operation of prefabricated substations, since the internal equipment usually comes from different manufacturers and uses different communication protocols, the protocol conversion module plays an important role.

[0095] Case 1: Assume the transformer monitoring equipment in a prefabricated substation uses the MODBUS protocol. When the local communication module collects data from this equipment, the protocol conversion module can quickly identify it as being in MODBUS format. Then, according to pre-set conversion rules, it parses and extracts key data such as transformer oil temperature, winding temperature, and load current. Next, it repackages this data into an internally unified protocol format so that the subsequent remote communication module can accurately upload it to the management platform, achieving effective integration and remote transmission of data from devices using different protocols.

[0096] Case 2: For low-voltage smart meters using the DLT645 protocol, the protocol conversion module can accurately identify the protocol, extract voltage, current, power, and other electrical data, and convert them into a unified format. For example, when power companies analyze grid operation data, they need to aggregate data from multiple prefabricated substations, including data from different meters. This module's conversion function enables unified processing of this data, providing a data foundation for optimizing grid operation strategies, enhancing data processing compatibility, improving the overall intelligent management level of prefabricated substations, ensuring efficient data interaction, and helping power companies better manage and monitor the operating status of prefabricated substations.

[0097] Implementation method four, combined with implementation method four and appendix Figure 7 The details are as follows:

[0098] 1. Implementation Method Four

[0099] 1.1 Combining Implementation Method 4 and Appendix Figure 7 The protocol conversion module is described in detail.

[0100] 1.1.1 Protocol Conversion Module (Appendix) Figure 7 )

[0101] The protocol conversion module plays a crucial role in data format conversion within the communication management unit of the prefabricated substation. (See attached...) Figure 7 As shown, it has multiple built-in parsing protocols, which are of great significance for realizing data interaction and overall management between different devices in the prefabricated substation.

[0102] Case 1: In a prefabricated substation, the high-voltage side microprocessor-based protection device may employ a specific industrial communication protocol, while the control platform used by the monitoring center may receive and process data based on a different general protocol. When the high-voltage side microprocessor-based protection device transmits protection action information such as overcurrent and overvoltage, as well as real-time operating data, the protocol conversion module identifies and parses this data according to its built-in relevant parsing protocols, converting it into a format that the control platform can understand. For example, it converts the data from the high-voltage side microprocessor-based protection device into data conforming to the MQTT protocol format, and then accurately uploads it to the control platform via the remote communication module, enabling maintenance personnel to obtain the operating status and protection information of the high-voltage side equipment in a timely manner, achieving remote monitoring and management.

[0103] Case Study 2: Assuming the temperature and humidity sensors in the prefabricated substation use a manufacturer-defined protocol, the protocol conversion module plays a crucial role before transmitting the collected temperature and humidity data to the management platform. Based on built-in parsing rules, it converts the sensor data from the custom protocol to a standard protocol format such as DLT645, ensuring the data can be managed and analyzed uniformly with data from other devices. In practical applications, power companies can understand the environmental conditions of substations in different areas by uniformly analyzing temperature and humidity data from multiple prefabricated substations. This provides a basis for equipment maintenance and operation optimization, such as rationally scheduling equipment cooling maintenance, avoiding the impact of abnormal temperature and humidity on normal equipment operation, and improving the reliability and stability of the prefabricated substation operation.

[0104] Implementation method five, in combination with implementation method five and appendix Figure 8 The details are as follows:

[0105] 1. Implementation Method Five

[0106] 1.1 In conjunction with implementation method 5 and appendix Figure 8 A thorough analysis of the remote communication module.

[0107] 1.1.1 Remote communication module (attached) Figure 8 )

[0108] The remote communication module is a crucial bridge for data exchange between the prefabricated substation's communication management unit and external systems. (See attached image) Figure 8 As shown, at least one of its Ethernet ports plays a crucial role in data uploading and configuring communication management machine parameters.

[0109] Case 1: In daily operation, data from various equipment within a prefabricated substation, such as transformer oil temperature, high-voltage side voltage and current, and low-voltage side power factor, are collected, processed, and converted via the local communication module. Then, they are uploaded in real-time to a remote management platform using the TCP / IP protocol through the Ethernet port of the remote communication module. For example, data from numerous prefabricated substations in a city's power supply network can be continuously transmitted to the monitoring center. Maintenance personnel at the monitoring center can directly view the operating parameters of each substation, promptly identify anomalies, such as excessively high transformer oil temperature in a substation, and quickly dispatch maintenance personnel to handle the situation, greatly improving maintenance efficiency and ensuring the stability of power supply.

[0110] Case 2: When parameter configuration of the communication management unit in a prefabricated substation is required, technicians can send configuration commands to the Ethernet port via the network from the remote monitoring center. For example, based on the actual needs of the power grid operation, the frequency of data acquisition within the prefabricated substation can be adjusted, or parameters such as the communication baud rate can be modified. Upon receiving these commands, the remote communication module accurately transmits them to the communication management unit, enabling it to operate according to the new configuration. This avoids the inconvenience of technicians frequently visiting the site for configuration, reduces operation and maintenance costs, and also improves the timeliness and accuracy of configuration, adapting to the ever-changing operational needs of the power system and ensuring the coordinated operation of the prefabricated substation with the entire power network.

[0111] Implementation method six, in combination with implementation method six and appendix Figure 9 The details are as follows:

[0112] 1. Implementation Method Six

[0113] 1.1 In conjunction with Implementation Method 6 and Appendix Figure 9 The Real-Time Clock (RTC) module is described in detail.

[0114] 1.1.1 Real-time Clock (RTC) Module (with) Figure 9 )

[0115] The Real-Time Clock (RTC) module provides a precise time reference for the communication management unit of the prefabricated substation, which is of great significance for data acquisition and analysis. (See attached...) Figure 9 As shown, its workflow is closely related to the operation of the entire communication management machine.

[0116] Case 1: During the operation of a prefabricated substation, when equipment malfunctions, the data acquisition and processing module records relevant data, such as voltage and current surges during short circuits on the high-voltage side. At this time, the real-time clock (RTC) module adds precise timestamps to this data, accurate to the second or even millisecond. Suppose a prefabricated substation experiences a short circuit fault at 15:30:20.50 on May 10, 2023. By reviewing the timestamped data, technicians can clearly understand the sequence of events and quickly analyze the cause of the fault. Without precise time records, technicians would find it difficult to accurately determine the order of events, potentially leading to difficulties in troubleshooting and impacting power restoration time.

[0117] Case Study 2: In regular data statistics and analysis, the time reference of the Real-Time Clock (RTC) module is also indispensable. For example, power companies need to statistically analyze the load changes of a prefabricated substation at different times of the day. Using the precise time provided by the RTC module, the load data collected by the data acquisition and processing module at each time point can be accurately categorized and analyzed. For instance, the load gradually increases from 8:00 AM to 9:00 AM, reaching its peak from 12:00 PM to 1:00 PM. Based on this accurate time-series data, power companies can optimize power dispatch strategies, rationally allocate power resources, improve grid operating efficiency, ensure that power supply meets demand at different times, and avoid power waste or insufficient supply.

[0118] Implementation method seven, in combination with implementation method seven and appendix Figure 10 The details are as follows:

[0119] 1. Implementation Method Seven

[0120] 1.1 In conjunction with Implementation Method 7 and Appendix Figure 10 An analysis of the Real-Time Clock (RTC) module.

[0121] 1.1.1 Real-time Clock (RTC) Module (with) Figure 10 )

[0122] The Real-Time Clock (RTC) module provides precise time management for the communication management unit of the prefabricated substation, and its circuit structure and functions are closely integrated. (See attached...) Figure 10 As shown, its working principle is based on components such as crystal oscillators to achieve precise timing.

[0123] Case 1: During the long-term stable operation of a prefabricated substation, when the main power supply is normal, the +3.3V power supply powers the RTC module and simultaneously charges the battery. Suppose that the area where the prefabricated substation is located suddenly experiences a short power outage, causing the main power supply to fail. However, because the battery immediately takes over the power supply, the RTC module continues to operate, and time information is not lost. When the power outage ends and power is restored, the communication management unit can still continue to work based on the accurate time provided by the RTC module, and the time sequence of data acquisition and recording remains accurate. This ensures that under various power supply conditions, the operating data of the prefabricated substation has accurate time stamps, facilitating subsequent analysis and management of the operating status, such as analyzing changes in equipment operating parameters before and after a power outage, and determining whether the equipment was affected by the power outage.

[0124] Case Study 2: In a multi-prefabricated substation joint monitoring scenario, the Real-Time Clock (RTC) modules of different substations provide accurate time. For example, in a large industrial park, there are multiple prefabricated substations, and data from each substation is transmitted to a centralized monitoring center via a network. Because the RTC module of each communication management unit has accurate time, the monitoring center can accurately compare data from different substations at the same time, such as the load status and equipment operating temperature of substations in different areas at the same time. This helps power operation and maintenance personnel to have a comprehensive understanding of the power supply status of the entire park, promptly detect regional power anomalies, conduct unified scheduling and management, ensure the normal production power supply of enterprises within the park, improve the reliability and stability of the entire park's power system, and avoid data misjudgment and incorrect decisions caused by time asynchrony.

[0125] Implementation method eight, in combination with implementation method eight and appendix Figure 11 The details are as follows:

[0126] 1. Implementation Method Eight

[0127] 1.1 In conjunction with implementation method 8 and appendix Figure 11 The components of the Real-Time Clock (RTC) module are described.

[0128] 1.1.1 Real-time Clock (RTC) Module Components (with appendix) Figure 11 )

[0129] The component composition of the Real-Time Clock (RTC) module determines its ability to provide accurate time for the communication management unit of the prefabricated substation. (See attached...) Figure 11 As shown, a crystal oscillator (such as U9) serves as the clock source, and together with capacitors (C19, C20, C21, etc.), they form a stable oscillation circuit.

[0130] Case 1: In a prefabricated substation located in a remote mountainous area, the complex environment and strong electromagnetic interference make the stable oscillation frequency of the crystal oscillator unaffected by external interference, consistently providing a precise timing basis for the RTC module. For example, during summer thunderstorms, the strong electromagnetic interference generated by lightning may affect the normal operation of other equipment in the substation, but the RTC module, thanks to the stability of the crystal oscillator, can still accurately keep time. When equipment malfunctions, such as a transformer malfunctioning due to a lightning strike, while the data acquisition and processing module collects fault data, the RTC module can accurately record the time of the fault occurrence. This provides a reliable basis for subsequent maintenance personnel to determine the time of the fault and analyze its cause, facilitating the rapid restoration of power supply.

[0131] Case Study 2: In urban power grids, prefabricated substations are widely distributed and numerous. For power companies to achieve refined grid management, the Real-Time Clock (RTC) module components of the communication management units in each prefabricated substation must maintain a high degree of synchronization. The high precision of the crystal oscillator ensures the accuracy of timing across different RTC modules. For example, when conducting nationwide power load statistics, each substation needs to accurately record load data at the same time. The RTC module, relying on the crystal oscillator and related components, enables each station to collect data simultaneously, ensuring data consistency and validity. Based on this accurately synchronized data, power companies can optimize grid operation, rationally allocate power resources, improve overall grid operating efficiency, meet the electricity needs of urban residents and businesses, and avoid power dispatching errors caused by time asynchrony.

[0132] Implementation method nine, in combination with implementation method nine and appendix Figure 12 The details are as follows:

[0133] 1. Implementation Method Nine

[0134] 1.1 Combining Implementation Method 9 and Appendix Figure 12 A detailed explanation of the FLASH storage module.

[0135] 1.1.1 FLASH storage module (attached) Figure 12 )

[0136] The FLASH storage module plays a crucial role in data storage within the communication management unit of the prefabricated substation. Its communication method with the MCU ensures effective data management. (See attached image.) Figure 12 As shown, data is exchanged with the MCU via the SPI bus.

[0137] Case 1: In the daily operation of a prefabricated substation, equipment operating data, including high-voltage side voltage and current, and low-voltage side power, is collected at regular intervals (e.g., every 5 minutes). After processing by the data acquisition and processing module, the MCU sends write commands to the FLASH storage module via the SPI bus, storing the data byte by byte into the FLASH chip. For example, when analyzing the voltage fluctuations of a prefabricated substation over a week, technicians can accurately read the data for the corresponding time period from the FLASH storage module through the MCU, providing data support for analyzing the causes of voltage fluctuations, such as determining whether there are problems like voltage drops during peak electricity consumption periods, so that appropriate measures can be taken, such as adjusting transformer taps, to ensure the quality of power supply.

[0138] Case 2: When the communication management unit of the prefabricated substation undergoes a software upgrade, the new program code is first downloaded to the FLASH storage module. Assuming a brief network interruption occurs during the upgrade process, since the FLASH storage module has already stored some of the downloaded program data, the download can resume from the point of interruption after the network is restored, without data loss. After the upgrade is complete, the FLASH storage module can also store information such as software upgrade records. During subsequent operation and maintenance, if system anomalies occur, technicians can check the upgrade records in the FLASH to determine if the problem was caused by the upgrade process. This helps to quickly locate and resolve faults, ensuring the stable operation of the prefabricated substation communication management unit, reducing the risk of power outages due to system failures, and improving the reliability of power supply.

[0139] Implementation method ten, in combination with implementation method 10 and appendix Figure 13 The details are as follows:

[0140] 1. Implementation Method Ten

[0141] 1.1 In conjunction with implementation method 10 and appendix Figure 13 The hardware self-transmit and receive control circuit is analyzed.

[0142] 1.1.1 Hardware self-transmit / receiver control circuit (attached) Figure 13 )

[0143] The hardware-based self-transmitting control circuit plays a crucial role in ensuring the secure isolation of the 485 communication system of the prefabricated substation's communication management unit. (See attached image.) Figure 13 As shown, it includes components such as isolated power supply and optocoupler isolation.

[0144] Case 1: In a prefabricated substation within an industrial plant, numerous large electrical devices, such as motors and welding machines, generate strong electromagnetic interference during operation. When the communication management unit interacts with equipment within the substation (such as switchgear status monitoring devices) via RS-485 communication, the optocoupler isolation in the hardware self-transmitting control circuit effectively prevents external electromagnetic interference signals from entering the communication line. For example, the high-frequency interference signals generated by the welding machine do not affect RS-485 communication, ensuring that the switchgear status monitoring device can accurately transmit data such as switch opening and closing status to the communication management unit. Simultaneously, it ensures that the control commands sent by the communication management unit accurately reach the switchgear, guaranteeing the normal operation of the equipment and the accuracy of monitoring.

[0145] Case 2: In a distributed power system composed of multiple prefabricated substations, potential differences may exist between different substations. The isolation power supply of the hardware-based self-transmitting control circuit can prevent problems such as current backflow caused by potential differences. For example, when an anomaly occurs in the grounding system of a substation, causing a potential rise, the isolation power supply can ensure that the RS-485 communication of the communication management unit within that substation is unaffected, and communication with other substations remains stable and reliable. In this way, the monitoring center can obtain real-time operating data from each substation, such as transformer oil temperature and load conditions, achieving unified management and monitoring of the entire distributed power system. This ensures the safe and stable operation of the power system, avoids power accidents caused by communication failures, and improves the reliability and continuity of power supply.

Claims

1. A prefabricated substation communication management unit, characterized in that, include: The local communication module is used for data acquisition and communication with equipment in the prefabricated substation; the local communication module has at least 8 independent serial ports and has RS485 communication function. The data acquisition and processing module is used to acquire data from the high-voltage side microprocessor protection, transformer temperature control, temperature and humidity sensors, high-voltage side meters, and low-voltage side meters. The protocol conversion module is used to convert the collected data into the protocol data format required by the management and control platform; the protocol conversion module has built-in multiple parsing protocols, including one or more of MODUBS, DLT645, MQTT, and ICE104; A remote communication module is used to transmit processed data to a remote or local area network management platform via a network port; the remote communication module includes at least one Ethernet port for data uploading and configuring communication management machine parameters; The remote upgrade module is used to enable remote upgrades and maintenance of the communication management unit; after the remote upgrade module opens a whitelist on the network, the on-site communication management unit connects to the remote upgrade server; The Real-Time Clock (RTC) module is used to provide real-time time. The real-time clock (RTC) module uses a crystal oscillator as the clock source and is powered by a battery when the main power supply fails. The Real-Time Clock (RTC) module provides a precise time base for the entire system, enabling accurate timestamps for each data point during data acquisition and recording. The FLASH storage module is used to store data from remote upgrades, collected data, system configuration parameters, and operation logs. The program download and error printing interface is used to implement program download and error message printing. The communication management unit has a hardware self-transmit and receive control circuit, as well as isolated power supply and optocoupler isolation to ensure secure isolation of 485 communication.

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