Multifunctional boiler interlock device

Abstract

This utility model discloses a multifunctional boiler interlocking device, including a control panel, a dual-color water level display, a sensor module, an interlocking control unit, an audible and visual alarm, and an output terminal group. The sensor module includes high-temperature resistant electrode rods and can detect water level in environments with pressure ≤2.5MPa and temperature ≤225℃. An electrical contact pressure gauge monitors the air pressure. After receiving the signal, the interlocking control unit controls the water pump to automatically add and stop water via a water level range selection switch to maintain a normal water level. It features five audible and visual alarm states; in case of abnormality, it cuts off the power to the equipment and triggers an alarm. The control panel has a manual / automatic switch and a dual-pump switch, supporting manual intervention and redundant pump switching, with adjustable volume. Interlocking protection ensures automatic boiler shutdown in dangerous situations, improving the safety and reliability of boiler operation.

Description

Technical Field

[0001] This utility model relates to the field of boiler safety control technology, specifically to a multi-functional boiler interlocking device. Background Technology

[0002] Small and medium-sized steam boilers are widely used in industrial production and heating, and their safe and stable operation is directly related to the normal operation of production and the safety of people's lives and property. Currently, traditional control devices for small and medium-sized steam boilers have many shortcomings. Regarding water level control, ordinary water level gauges often use a single color display, making it difficult to distinguish the water level status when the boiler is full, short of water, or experiencing boiler-water overflow, which can easily lead to misjudgment by the boiler operator and consequently cause safety accidents.

[0003] The existing alarm system has a fixed alarm volume, which cannot be adjusted according to the noise level in the boiler room control room. In noisy environments, it may not attract the attention of the boiler operator in time, while in quiet environments, it may cause noise pollution. At the same time, the propagation distance of the alarm signal is unstable, making it difficult to ensure that alarm information is effectively transmitted under different environmental conditions.

[0004] Regarding water pump control, most units are equipped with only a single pump. A pump malfunction will directly affect the boiler's water supply, causing it to malfunction. Furthermore, the existing units lack flexibility in switching between automatic and manual control. In dangerous situations such as low water levels, ultra-low water levels, and overpressure, the control logic is not rigorous enough, often failing to promptly cut off power to relevant equipment according to a proper procedure, posing significant safety hazards. Moreover, the lack of effective limit interlock protection control means that when the boiler is in dangerous conditions such as overpressure or severe water shortage, it cannot reliably shut down automatically until the fault is cleared, making it difficult to guarantee the boiler's absolute safety. Utility Model Content

[0005] The present invention aims to solve the above-mentioned technical problems by providing a multi-functional boiler interlocking device that integrates multiple functions such as water level monitoring and regulation, pressure monitoring, audible and visual alarms, water pump switching, and interlocking protection. It can realize automated control and safety protection during boiler operation, ensuring the safe, stable, and economical operation of the boiler under various working conditions. It is widely used in industrial production, heating, and other scenarios that require small and medium-sized steam boilers.

[0006] To solve the above-mentioned technical problems, the technical solution provided by this utility model is: a multi-functional boiler interlocking device, comprising: The control panel integrates a power switch, a manual / automatic switch, a water pump switch, a water level range selection switch, a manual water supply / stop button, an alarm silence button, and a volume control knob. The dual-color water level display uses a red-green high-brightness color-changing tube to visualize the water level, making steam appear red and water green. The sensor module includes high-temperature resistant electrode rods and flange interfaces, with a working pressure ≤2.5MPa and a temperature tolerance ≤225℃; An interlocking control unit is electrically connected to an electric contact pressure gauge and an audible and visual alarm, wherein the electric contact pressure gauge has a range of 0-1.6 MPa; The output terminal block supports 220V / 3A and 380V / 1.5A inductive loads.

[0007] Furthermore, the interlocking control unit performs: A high water level alarm is triggered when the water level is greater than +60mm. When the water level is <60mm, a low water level alarm is triggered and the following actions are taken: the water pump power is cut off, the blower and grate are stopped, and the induced draft fan is stopped after a 5-30 second delay. When the water level is less than 80 mm, an ultra-low water level alarm is triggered. When the pressure exceeds the set threshold, the burner power is cut off and an overpressure alarm is triggered.

[0008] Furthermore, the sensor module includes: At least three vertically installed electrode rods, with insulation resistance between electrodes and between electrodes and cylinder > 0.8 MΩ; The high-temperature resistant signal cable is covered with a silicone sheath and connects to the control panel via a numbered aviation connector.

[0009] Furthermore, the water level range selection switch has a dual-position switching structure: First setting: Automatic water filling starts when the water level is below 30mm and stops when it is above +30mm; Second setting: Start water supply when the water level is 0, and stop when it is above +45mm.

[0010] Furthermore, the audible and visual alarm device satisfies: Daytime propagation distance: ≥50 meters in quiet environments, ≥300 meters in noisy environments; The transmission distance at night is ≥50 meters; Operating environment: 30℃ to +50℃, relative humidity ≤88%.

[0011] Furthermore, the manual / automatic selector switch in automatic mode: Manual mode is forcibly locked before the ultra-low water level / low water level fault is resolved; Manual intervention in starting and stopping the water pump is permitted within the normal water level range.

[0012] The advantages of this utility model compared with the prior art are as follows: it solves the problem of difficulty in identifying water level using traditional water level gauges through dual-color water level display; it ensures water supply with dual-pump redundancy; it allows for flexible automatic / manual switching and rigorous interlocking logic, stopping the equipment according to the procedure in case of danger; and it has an adjustable volume alarm to adapt to different environments, effectively solving the defects of the prior art and improving the safety and reliability of the boiler. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the multifunctional boiler interlocking device of this utility model.

[0014] Figure 2 This is an installation diagram of the multi-functional boiler interlocking device of this utility model.

[0015] Figure 3 This is a schematic diagram of the working process of the multifunctional boiler interlocking device of this utility model. Detailed Implementation

[0016] To make the technical problems, technical solutions, and beneficial effects of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0017] 0. Working principle of this utility model: The core principle of this multi-functional boiler interlocking device is to achieve real-time monitoring, automatic adjustment, and safety protection of key parameters such as boiler water level and pressure through the coordinated operation of multiple modules. The device mainly consists of a control panel 1, a dual-color water level display 2, sensor modules, an interlocking control unit, an audible and visual alarm 6, and output terminal blocks.

[0018] The sensor module comprises at least three vertically mounted electrode rods with an insulation resistance >0.8MΩ between electrodes and between electrodes and the boiler body. It connects to control panel 1 via a high-temperature resistant signal cable covered with a silicone sheath and a numbered aviation connector. It can accurately detect the water level signal inside the boiler in environments with operating pressure ≤2.5MPa and a temperature tolerance ≤225℃, and transmit the signal to the interlock control unit. Simultaneously, an electrical contact pressure gauge with a range of 0-1.6MPa is electrically connected to the interlock control unit to monitor the gas pressure inside the boiler in real time and provide feedback signals.

[0019] The interlocking control unit, as the core control component of the device, receives water level signals from the sensor module and pressure signals from the electrical contact pressure gauge, and then analyzes and processes them. When the water level is detected to be within the normal range, and the water level range selection switch 104 selects either the +30mm setting or the 0-+45mm setting, the control unit automatically adds or stops water according to the set logic to maintain a stable water level. The water level range selection switch 104 has a dual-position switching structure. In the first position, +30mm, automatic water addition is initiated when the water level is below -30mm and stops when it is above +30mm. In the second position, 0-+45mm, water addition is initiated when the water level is 0 and stops when it is above +45mm.

[0020] When an abnormal state occurs, the interlocking control unit triggers the corresponding control logic and alarm functions. When the water level is > +60mm, a high water level alarm is triggered, the warning light of the audible and visual alarm 6 flashes, and the horn sounds an alarm. When the water level is < -60mm, a low water level alarm is triggered, an ambulance siren sounds, and the power to the water pump is cut off, the blower and grate are stopped, and the induced draft fan stops after a 5-30 second delay. When the water level is < -80mm, an ultra-low water level alarm is triggered, a fire truck siren sounds, and the boiler is shut down in an emergency. When the pressure is > the set threshold, the burner power is cut off, and a machine gun-like steam pressure alarm sounds.

[0021] The manual / automatic switch 102 on control panel 1 switches between control modes. In automatic mode, manual mode is forcibly locked until the ultra-low water level / low water level fault is cleared. Manual intervention to start and stop the water pump is allowed within the normal water level range. In manual mode, the combustion system and water pump are not automatically controlled by the instrument, but the water level display, alarm, and other functions remain normal. The water pump switch 103 adopts a dual-pump redundancy design. If pump one fails, it can switch to pump two to maintain water supply. Both pumps share the same set of output terminals, which supports 220V / 3A and 380V / 1.5A inductive loads. The volume adjustment knob 107 is a linear potentiometer that adjusts the alarm volume according to ambient noise. The alarm silence button 106 can be pressed once to turn off the alarm sound. The alarm light automatically turns off after the water level / pressure returns to normal.

[0022] 0. Implementation method: The control panel 1 integrates a power switch 101, a manual / automatic switch 102, a water pump switch 103, a water level range selection switch 104, a manual water supply / stop button 105, an alarm silence button 106, and a volume adjustment knob 107. It is made of industrial-grade materials to ensure stable operation in an environment with an ambient temperature of -30℃ to +50℃ and a relative humidity of <88% to 40℃.

[0023] The dual-color water level indicator 2 uses red-green high-brightness color-changing tubes and is installed in a prominent position on the control panel 1 to achieve a visual display of the water level with "red for steam and green for water." When steam and water bubbling occurs in the boiler, it can clearly show irregular changes, making it easy for the boiler operator to detect in time. The electrode rods of the sensor module are made of high-temperature and corrosion-resistant stainless steel and are installed vertically in a suitable position on the boiler. The insulation resistance between electrodes and between the electrodes and the boiler body must be greater than 0.8MΩ. Before installation, it must be tested with a multimeter on the Rx10K range. The high-temperature resistant signal wire is covered with a silicone sheath and is connected to the top of the sensor flange and the aviation connector on the rear cover of the instrument according to the corresponding numbers. When wiring, apply moderate force to prevent the electrode rod from rotating and causing contact with the electrode or short circuit.

[0024] An electric contact pressure gauge is installed at the boiler's pressure detection port, with a range of 0-1.6 MPa. The two pointers are set within the specified pressure range using adjusting screws, and its output signal is connected to the interlocking control unit. An audible and visual alarm 6 is installed in the boiler room control room and nearby in easily detectable locations, ensuring a propagation distance of ≥50 meters in quiet environments during the day, ≥300 meters in noisy environments, and ≥50 meters at night. It is electrically connected to the interlocking control unit, receiving control signals and emitting corresponding audible and visual alarms.

[0025] The output terminal block is located at the rear of the device. Connect it to the water pump motor, blower, grate, induced draft fan, burner, and other equipment according to the wiring diagram, ensuring support for 220V / 3A and 380V / 1.5A inductive loads. After assembly, perform a wiring check to ensure reliable connections and good insulation between wires.

[0026] During operation, turn the power switch 101 to the top to put the instrument into operation. Select the control mode as needed using the manual / automatic switch 102. In automatic mode, when the boiler is out of the "ultra-low water level" or "low water level" range, the induced draft fan, forced draft fan, and grate can be activated to automatically control the boiler water supply. Within the normal water level range, the water pump can be manually intervened using the manual water supply / stop button 105. When a fault alarm occurs, the boiler operator can press the alarm silence button 106 to turn off the alarm sound; the alarm light will automatically turn off after the parameters return to normal. The alarm volume can be adjusted according to the ambient noise level using the volume control knob 107; clockwise rotation increases the volume, and counterclockwise rotation decreases it until it is silent. When pump number one malfunctions, switch to pump number two using the pump transfer switch 103 to ensure normal boiler water supply. The sensors must be flushed once per shift; during flushing, turn off the power switch 101 to prevent control malfunction.

[0027] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the inventive spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. Multifunctional boiler interlocking device, characterized by: include: The control panel (1) integrates a power switch (101), a manual / automatic switch (102), a water pump switch (103), a water level range selection switch (104), a manual water supply / water stop button (105), an alarm silence button (106), and a volume adjustment knob (107). The dual-color water level display (2) uses a red-green high-brightness color-changing tube to visualize the water level, making the steam appear red and the water appear green. The sensor module includes high-temperature resistant electrode rods and flange interfaces, with a working pressure ≤2.5MPa and a temperature tolerance ≤225℃; An interlocking control unit is electrically connected to an electric contact pressure gauge and an audible and visual alarm, wherein the electric contact pressure gauge has a range of 0-1.6 MPa; The output terminal block supports 220V / 3A and 380V / 1.5A inductive loads.

2. The multifunction boiler interlock device according to claim 1, characterized by: The interlocking control unit performs: A high water level alarm is triggered when the water level is greater than +60mm. When the water level is <60mm, a low water level alarm is triggered and the following actions are taken: the water pump power is cut off, the blower and grate are stopped, and the induced draft fan is stopped after a 5-30 second delay. When the water level is less than 80 mm, an ultra-low water level alarm is triggered. When the pressure exceeds the set threshold, the burner power is cut off and an overpressure alarm is triggered.

3. The multifunction boiler interlock device according to claim 1, characterized by: The sensor module includes: At least three vertically installed electrode rods, with insulation resistance between electrodes and between electrodes and cylinder > 0.8 MΩ; The high-temperature resistant signal cable is covered with a silicone sheath and connects to the control panel via a numbered aviation connector.

4. The multifunction boiler interlock device according to claim 1, characterized by: The water level range selection switch (104) has a dual-position switching structure: First setting: Automatic water filling starts when the water level is below 30mm and stops when it is above +30mm; Second setting: Start water supply when the water level is 0, and stop when it is above +45mm.

5. The multifunction boiler interlock device according to claim 1, characterized by: The audible and visual alarm (6) satisfies: Daytime propagation distance: ≥50 meters in quiet environments, ≥300 meters in noisy environments; The transmission distance at night is ≥50 meters; Operating environment: 30℃ to +50℃, relative humidity ≤88%.

6. The multifunction boiler interlock device according to claim 1, characterized by: The manual / automatic selector switch (102) in automatic mode: Manual mode is forcibly locked before the ultra-low water level / low water level fault is resolved; Manual intervention in starting and stopping the water pump is permitted within the normal water level range.

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