A hardware architecture of a junction box waterproof monitoring system based on a SCADA system

Abstract

The utility model provides a kind of hardware architecture of waterproof monitoring system of terminal box based on SCADA system, it is related to terminal box waterproof monitoring technical field, comprising: humidity monitoring device in terminal box, it is equipped with high-precision humidity digital probe, the shell of high-precision humidity digital probe is waterproof seal structure, and adjustable fixed support is installed in terminal box inner wall by;Station SCADA system monitoring module, including station SCADA system communication server, station operating station, serial server and PCS system;Humidity monitoring device is connected with serial server and PCS system by RS485 signal line;Station SCADA system communication server is respectively communicated with serial server, PCS system and station operating station by network cable.The efficient collection and stable transmission of humidity data are realized by modular structure design, standardized connection interface and high protection grade shell, meet the waterproof monitoring needs of terminal box.

Description

Technical Field

[0001] This utility model relates to the field of waterproof monitoring technology for junction boxes, and in particular to a hardware architecture for a waterproof monitoring system for junction boxes based on a SCADA system. Background Technology

[0002] The statements in this section are merely background information relating to this disclosure and do not necessarily constitute prior art.

[0003] Currently, there are many junction boxes for SCADA system data acquisition equipment in the process areas of various gas transmission stations. When severe weather occurs, such as heavy rain or typhoons, rainwater may enter the junction boxes, causing short circuits in the wiring and corrosion damage to the equipment, posing a safety hazard to the operation of the station equipment.

[0004] In existing technologies, waterproof monitoring of junction boxes mostly relies on manual inspections or single sensor alarms, which has the following drawbacks:

[0005] (1) During manual inspection, the explosion-proof junction box needs to be opened frequently to check the sealing performance and internal humidity. However, opening the cover requires disassembling multiple sealing bolts, which is complicated and time-consuming (the time for junction boxes with many bolts can be as long as 20-28 minutes), resulting in low inspection efficiency.

[0006] (2) The single sensor is installed independently and lacks a fixed structure that is compatible with the internal space of the junction box. It is easy to loosen or fail due to environmental factors. Utility Model Content

[0007] To address the shortcomings of existing technologies, this utility model proposes a hardware architecture for a junction box waterproof monitoring system based on a SCADA system. By adding a humidity acquisition unit inside the junction box, the system detects the humidity of the internal equipment, collects humidity data, and performs real-time analysis to determine whether the humidity is rising sharply or linearly. If the humidity exceeds the preset value of the humidity acquisition device inside the junction box, it determines whether the waterproof performance of the junction box has deteriorated or water has entered the box. The system provides early warnings for abnormal conditions such as deteriorated waterproof performance or water ingress, and issues alarms in the SCADA system of the site. The system can also remotely locate abnormal junction boxes and perform targeted opening and handling to improve inspection efficiency.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] A hardware architecture for a junction box-based waterproof monitoring system based on a SCADA system includes:

[0010] The humidity monitoring device inside the junction box is equipped with a high-precision digital humidity probe. The outer shell of the high-precision digital humidity probe is a waterproof and sealed structure, and it is installed on the inner wall of the junction box by an adjustable fixing bracket.

[0011] The monitoring module of the SCADA system at the site includes the SCADA system communication server, the site operator station, the serial port server, and the PCS system;

[0012] The humidity monitoring device is connected to the serial port server and the PCS system via an RS485 signal line; the station SCADA system communication server communicates with the serial port server, the PCS system and the station operator station via network cables.

[0013] Furthermore, the RS485 signal line includes a 4-core shielded cable, comprising two power supply cores and two signal transmission cores, with an outer tensile braided layer, and the connectors at both ends are made of waterproof metal.

[0014] Furthermore, it also includes a central SCADA system monitoring module, comprising: a core switch, a central operator station, a real-time server, a central SCADA system communication server, a disk array, and a historical server. The central SCADA system monitoring module is connected to the field SCADA system monitoring module via optical transmission equipment.

[0015] The core switch communicates with the central operation station, real-time server, central SCADA system communication server, and historical server via network cables; the core switch is also connected to the disk array via optical fiber.

[0016] Furthermore, the optical transmission equipment includes a site router and a central router. The site router is connected to the central router and the site communication server via optical cables, and the central router is connected to the core switch via optical cables.

[0017] Furthermore, it also includes an OAD remote terminal for the management office, which is connected to the central router via optical fiber.

[0018] Furthermore, the adjustable fixing bracket includes a base, an adjustable arm, and a probe fixing base;

[0019] The base is fixed to the inner wall of the junction box, and the base is provided with a transverse sliding groove.

[0020] The adjustable arm is connected to the base via a slider;

[0021] The probe mounting base is located at the end of the adjusting arm and is used to fix the high-precision digital humidity probe with screws or clips.

[0022] Compared with the prior art, the hardware architecture of the junction box waterproof monitoring system based on SCADA system provided by this utility model has the following advantages:

[0023] (1) This utility model significantly reduces the frequency of manual unpacking and inspection by real-time humidity monitoring and linkage alarm with the SCADA system. Traditional maintenance requires the removal of multiple bolts (a single inspection of a junction box with many bolts takes 20-28 minutes), while this system can directly locate abnormal junction boxes through remote alarm, requiring only targeted unpacking and handling, thus significantly improving maintenance efficiency.

[0024] (2) In the prior art, the connection between the monitoring device and the SCADA system relies on complex wiring, making it difficult to quickly access the existing industrial automation network. This utility model achieves standardization of the connection method between the junction box monitoring device and the SCADA system through modular structural design and standardized connection interface. This hardware architecture supports rapid access to the existing industrial automation network. At the same time, through components such as serial port server and router, it realizes efficient connection and data sharing between the humidity monitoring device in the junction box, the field operation station and the central operation station, which facilitates the expansion and upgrading of the system.

[0025] (3) In the prior art, signal transmission mostly uses ordinary cables, which have poor anti-interference capabilities and are susceptible to electromagnetic interference or physical damage during long-distance communication. This utility model uses a 4-core shielded cable for signal transmission, which enhances anti-interference capabilities and ensures stable data transmission even in long-distance communication or complex electromagnetic environments. The metal waterproof joint and tensile braided layer improve the cable's durability and protection level. Attached Figure Description

[0026] The accompanying drawings, which form part of this disclosure, are used to provide a further understanding of this disclosure. The illustrative embodiments of this disclosure and their descriptions are used to explain this disclosure and do not constitute an undue limitation of this disclosure.

[0027] Figure 1 This is a schematic diagram of the hardware architecture of a junction box waterproof monitoring system based on a SCADA system disclosed in this utility model. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0029] Example 1

[0030] This application provides a typical implementation of a hardware architecture for a junction box waterproof monitoring system based on a SCADA system. By adding a humidity acquisition unit inside the junction box, the system detects the humidity of the internal equipment, collects humidity data, and performs real-time analysis to determine whether the humidity is rising sharply or linearly. If the humidity exceeds the preset value of the humidity acquisition device inside the junction box, it determines whether the waterproof performance of the junction box has deteriorated or water has entered the box. The system provides early warnings for abnormal conditions such as deteriorated waterproof performance or water ingress, and issues alarms in the SCADA system of the site. The system can also remotely locate abnormal junction boxes and perform targeted opening and handling to improve inspection efficiency.

[0031] Real-time analysis of humidity data is an existing technology, and this application does not improve the data analysis method. In addition, the humidity inside the explosion-proof junction box is normally between 20% and 30%. Considering the condensation effect of metal materials and continuous rainy weather, the inventors' team set the humidity alarm value inside the explosion-proof junction box to 70% based on practical experience.

[0032] like Figure 1 The hardware architecture of a junction box waterproof monitoring system based on a SCADA system includes:

[0033] The humidity monitoring device inside the junction box is equipped with a high-precision digital humidity probe. The housing of the high-precision digital humidity probe is a waterproof and sealed structure, and it is installed on the inner wall of the junction box through an adjustable fixing bracket. The combination of the high-precision digital humidity probe and the waterproof and sealed structure ensures that the humidity inside the junction box can be accurately monitored even under harsh weather conditions, thereby improving the reliability of the monitoring data.

[0034] The monitoring module of the SCADA system at the site includes the SCADA system communication server, the site operator station, the serial port server, and the PCS system;

[0035] The humidity monitoring device is connected to the serial port server and the PCS system via an RS485 signal line; the station SCADA system communication server communicates with the serial port server, the PCS system and the station operator station via network cables.

[0036] The junction box waterproof monitoring device uses a high-precision digital probe, which has good long-term stability and anti-interference ability. It is compact, easy to install and operate. The power supply and output have overvoltage protection and reverse connection protection design. It adopts RS485 output mode, which can support a communication distance of up to 1200 meters, meeting the distance between the junction box and the cabinet in the field.

[0037] The RS485 signal cable comprises a 4-core shielded cable, including two power supply cores and two signal transmission cores, with an outer tensile braided layer and waterproof metal connectors at both ends. The 4-core shielded cable design enhances the signal's anti-interference capability, ensuring data stability and accuracy during long-distance transmission. The power supply cores provide power (12-36VDC wide voltage), while the signal transmission cores are used for RS485 output. Through a spare cable core in the junction box, it connects to the RS485 card or serial server in the cabinet and the local display screen in the control room. The local PLC, the site SCADA system communication server, and the local display screen read relevant data, displaying real-time data through the HMI interface, establishing trend archiving, alarm classification, and historical query functions.

[0038] Table 1 compares the RS485 signal cable (4-core shielded cable) provided by this utility model with the conventional RS485 signal cable (2-core).

[0039]

[0040] The cable provided by this utility model integrates power supply and signal transmission. It achieves high anti-interference performance and mechanical strength through double-layer shielding and a tensile braided layer, making it suitable for complex industrial environments. The nylon braided layer can withstand a tensile force of ≥500N, preventing core breakage due to pulling during installation or maintenance. The braided layer resists friction from the metal edges inside the junction box, extending the cable's service life. The stainless steel shell and silicone sealing ring prevent moisture and dust intrusion, making it suitable for high-humidity and dusty environments. The metal shell and shielding layer are directly conductive, forming a continuous electromagnetic shielding path and reducing signal attenuation.

[0041] The shielding design of the RS485 signal line in this application includes:

[0042] 1. Double-layer shielding structure:

[0043] Inner aluminum foil shielding: tightly wraps the wire core, with a coverage rate of ≥95%, reflecting high-frequency electromagnetic interference (such as noise generated by frequency converters and motors);

[0044] Outer copper mesh shielding: coverage ≥80%, weaving density 60 mesh, absorbs low-frequency interference (such as power frequency electromagnetic fields);

[0045] 2. Grounding of the shielding layer:

[0046] Both ends of the cable are connected to the equipment casing through metal waterproof connectors to form an equipotential grounding loop, which conducts the interference current to the ground.

[0047] An independent grounding copper busbar is installed inside the station cabinet to ensure that the grounding resistance is ≤1Ω and to avoid ground loop interference.

[0048] The hardware architecture of the junction box waterproof monitoring system based on SCADA also includes a central SCADA system monitoring module, which includes: a core switch, a central operator station, a real-time server, a central SCADA system communication server, a disk array, and a historical server. The central SCADA system monitoring module is connected to the field SCADA system monitoring module through optical transmission equipment. The central SCADA system monitoring module realizes centralized management and remote monitoring of junction box waterproof monitoring data, improving monitoring efficiency and response speed.

[0049] The core switch communicates with the central operation station, real-time server, central SCADA system communication server, and historical server via network cables; the core switch is also connected to the disk array via optical fiber.

[0050] The optical transmission equipment includes a site router and a central router. The site router is connected to the central router and the site communication server via optical cables, and the central router is connected to the core switch via optical cables.

[0051] The site SCADA system communication server and the central SCADA system monitoring module are further connected by a site firewall and a central firewall. The site firewall connects to the central firewall via an encrypted communication protocol, the specific content of which is existing technology. By adopting a dual firewall architecture and encrypted communication protocol, combined with access control, the security of data transmission from the site to the center is ensured, and external network attacks are resisted.

[0052] The hardware architecture of the junction box waterproof monitoring system based on the SCADA system also includes the management office OAD remote terminal, which is connected to the central router via optical fiber.

[0053] The adjustable fixing bracket includes a base, an adjustable arm, and a probe fixing base;

[0054] The base is fixed to the inner wall of the junction box, and the base is provided with a transverse sliding groove to support horizontal movement;

[0055] The adjustable arm is connected to the base via a slider and can slide horizontally along the slide groove; the arm body achieves vertical angle adjustment (0°~90°) through a hinge structure and is locked in position by a knob.

[0056] The probe mounting base is located at the end of the adjusting arm and uses screws or clips to fix the high-precision digital humidity probe.

[0057] The adjustable mounting bracket adapts to diverse spatial structures. Through the horizontal sliding groove on the base and the hinge structure of the adjustable arm (supporting horizontal sliding and vertical angle adjustment from 0° to 90°), the bracket can flexibly adapt to the internal space of different types of junction boxes (such as narrow areas and areas with dense cables). For example, in a pressure regulating skid explosion-proof junction box, the probe can avoid valve components and accurately locate weak points in the seal (such as the edge of the cover plate), avoiding installation failures or monitoring blind spots caused by size mismatches of traditional mounting brackets.

[0058] The same bracket can be adapted to various junction boxes of different sizes throughout the station (such as chromatography analysis cabins, metering skids, etc.) without customization, reducing redundant spare parts inventory and installation complexity caused by model differences. The adjustable arm is locked in position via a knob, and the base is bolted to the inner wall of the box. Combined with vibration-resistant materials (such as a stainless steel base), it effectively resists equipment vibration or external impact, preventing probe displacement or detachment. In the high-frequency vibration environment of gas transmission stations, traditional independent sensors are prone to data fluctuations due to unstable fixing, while this bracket can control displacement error within ±1mm.

[0059] The inventors' team compiled statistics on the time spent on disassembling and assembling the cover of the explosion-proof junction box during maintenance (Table 2).

[0060] Table 2. Statistics on the Inspection and Disassembly Time of Explosion-proof Junction Boxes

[0061]

[0062]

[0063] Table 2 shows that during routine internal inspections of explosion-proof junction boxes, disassembly and reassembly occupy most of the time. For example, disassembling and reassembling bolts on the pressure regulating skid and the valve actuator power source explosion-proof junction box takes 28 minutes and 20 minutes respectively. Since there are multiple such junction boxes in the gas transmission station, opening and inspecting each one individually is extremely time-consuming. Therefore, station personnel only conduct external inspections of the explosion-proof junction boxes. This fails to detect problems such as seal failure and damage, hindering timely maintenance.

[0064] The working principle of this utility model is as follows:

[0065] The hardware architecture of the junction box waterproof monitoring system based on SCADA system provided by this utility model adopts a modular structure design, including a local monitoring module, a field SCADA system monitoring module, and a central SCADA system monitoring module.

[0066] The local monitoring module is deployed in the junction box and includes a humidity probe, an adjustable bracket and an RS485 signal cable, which is responsible for environmental data acquisition and local signal conversion.

[0067] The monitoring module of the site SCADA system consists of a serial port server, a PCS system, and a site SCADA server, which realizes data aggregation, preliminary processing, and site-level alarms.

[0068] The central SCADA system monitoring module integrates data from multiple sites through the core switch, supporting real-time monitoring, historical archiving, and cross-regional collaborative management.

[0069] Furthermore, the hardware architecture of this SCADA-based junction box waterproof monitoring system adopts a standardized connection interface: it uses the RS485 communication protocol, and the interface definition conforms to the Modbus RTU standard, making it compatible with mainstream industrial equipment (such as PLCs and HMIs). The wiring sequence and color coding of the 4-core shielded cable (e.g., red / black for power supply lines, green / white for signal lines) strictly follow the IEC 61158 standard, ensuring plug-and-play functionality. The data frame format and verification method seamlessly integrate with the SCADA system, requiring no additional protocol conversion module.

[0070] Specifically, the humidity monitoring device is installed in the junction box, connected to the RS485 card or serial server in the cabinet and the local display screen in the duty room via a spare cable core in the junction box. The cabinet provides 24VDC power to the site. The field RS485 signal is connected to the PCS system or serial server, and then enters the site's SCADA (Data Acquisition and Monitoring Control) system communication server. The data is transmitted to the site operator station, where real-time data is displayed on the HMI interface, and trend archiving, alarm classification, and historical query functions are established for convenient data monitoring by site personnel. Data from the site's SCADA communication server is transmitted to the central SCADA system communication server and the central operator station via optical transmission equipment, a central router, and a core switch. The HMI interface displays real-time data, and trend archiving, alarm classification, and historical query functions are established for convenient data monitoring by control center personnel. Data can also be transmitted to the management office's OAD remote terminal via a dedicated line between the SCADA system monitoring module and the management office's OAD remote terminal, facilitating data monitoring by management personnel.

[0071] In the description of this specification, the terms "connection", "installation", "fixing", "setting", etc. are interpreted in a broad sense. For example, "connection" can be a fixed connection or an indirect connection through an intermediate component without affecting the relationship between components and the technical effect. It can also be an integral connection or a partial connection. In such cases, those skilled in the art can understand the specific meaning of the above terms in this utility model or utility model according to the specific circumstances.

[0072] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A hardware architecture for a SCADA system based junction box water proofing monitoring system, characterized in that, include: The humidity monitoring device inside the junction box is equipped with a high-precision digital humidity probe. The outer shell of the high-precision digital humidity probe is a waterproof and sealed structure, and it is installed on the inner wall of the junction box by an adjustable fixing bracket. The monitoring module of the SCADA system at the site includes the SCADA system communication server, the site operator station, the serial port server, and the PCS system; The humidity monitoring device is connected to the serial port server and the PCS system via an RS485 signal line; the station SCADA system communication server communicates with the serial port server, the PCS system and the station operator station via network cables.

2. The hardware architecture of the junction box waterproof monitoring system based on SCADA system as described in claim 1, characterized in that, The RS485 signal line includes a 4-core shielded cable, comprising two power supply cores and two signal transmission cores, with an outer tensile braided layer and metal waterproof connectors at both ends.

3. The hardware architecture of the junction box waterproof monitoring system based on SCADA system as described in claim 1, characterized in that, It also includes a central SCADA system monitoring module, comprising: a core switch, a central operator station, a real-time server, a central SCADA system communication server, a disk array, and a historical server. The central SCADA system monitoring module is connected to the field SCADA system monitoring module via optical transmission equipment. The core switch communicates with the central operation station, real-time server, central SCADA system communication server, and historical server via network cables; the core switch is also connected to the disk array via optical fiber.

4. The hardware architecture of the junction box waterproof monitoring system based on the SCADA system as described in claim 3, characterized in that, The optical transmission equipment includes a site router and a central router. The site router is connected to the central router and the site communication server via optical cables, and the central router is connected to the core switch via optical cables.

5. The hardware architecture of the junction box waterproof monitoring system based on the SCADA system as described in claim 4, characterized in that, It also includes the management office OAD remote terminal, which is connected to the central router via optical fiber.

6. The hardware architecture of the junction box waterproof monitoring system based on SCADA system as described in claim 1, characterized in that, The adjustable fixing bracket includes a base, an adjustable arm, and a probe fixing base; The base is fixed to the inner wall of the junction box, and the base is provided with a transverse sliding groove. The adjustable arm is connected to the base via a slider; The probe mounting base is located at the end of the adjusting arm and is used to fix the high-precision digital humidity probe with screws or clips.

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