A remote control box based on 4G communication

Abstract

This application discloses a remote control box based on 4G communication, located within the cabinet of a frequency converter cabinet. The remote control box includes a cabinet, a power supply module, a 4G communication module, and a control module. The power supply module, 4G communication module, and control module are housed within the cabinet. The 4G communication module connects to an external control terminal via an RS485 interface. The power supply module is an AC165~480V wide voltage input module. The control module has digital input terminals and digital relay output terminals. In the digital relay output terminals, the normally open contact of the first relay output is connected in parallel to the start circuit of the frequency converter cabinet, and the normally closed contact of the second relay output is connected in series to the stop circuit of the frequency converter cabinet, thereby enabling the control module or external control terminal to control the start and stop of the frequency converter cabinet. The operating status signal of the frequency converter cabinet is fed back to the control module through the digital input terminals. This application improves the maintenance efficiency of frequency converter cabinet equipment.

Description

Technical Field

[0001] This application relates to the field of electromechanical equipment control and debugging technology, and in particular to a remote control box based on 4G communication. Background Technology

[0002] In the control and commissioning of variable frequency drive (VFD) cabinet equipment, parameters need to be frequently adjusted on-site. During operation, the VFD cabinet equipment also needs to be monitored, and the start and stop of the equipment are controlled based on the collected control parameters (flow rate, pressure, liquid level, VFD frequency). All of these tasks require the use of a PLC automatic control system to collect and debug them on-site. Moreover, the operators cannot see the status of the equipment at any time, which makes it impossible to detect equipment failures in time, leading to equipment abnormalities or even damage. Therefore, there is a deficiency in the low maintenance efficiency of VFD cabinet equipment, which urgently needs to be improved. Utility Model Content

[0003] To improve the maintenance efficiency of frequency converter cabinet equipment, this application provides a remote control box based on 4G communication.

[0004] This application provides a remote control box based on 4G communication, which adopts the following technical solution: A remote control box based on 4G communication is installed in the cabinet of a frequency converter cabinet. The remote control box includes a cabinet, a power supply module, a 4G communication module, and a control module. The power supply module, 4G communication module, and control module are located in the cabinet. The 4G communication module connects to an external control terminal via an RS485 interface. The power supply module is an AC165~480V wide voltage input module. The control module has digital input terminals and digital relay output terminals. In the digital relay output terminals, the normally open contact of the first relay output is connected in parallel to the start circuit of the frequency converter cabinet, and the normally closed contact of the second relay output is connected in series to the stop circuit of the frequency converter cabinet, so as to realize the start and stop control of the frequency converter cabinet by the control module or the external control terminal. The operating status signal of the frequency converter cabinet is fed back to the control module through the digital input terminals.

[0005] By adopting the above technical solution and using a power supply module with a wide voltage range of AC165~480V, the damage to components and control failures caused by unstable power supply voltage are effectively avoided. To improve the maintenance efficiency of frequency converter cabinets, this application provides a remote control box integrating a 4G communication module and a control module. Utilizing the 4G communication module and a remote control box with open control logic, the traditional frequency converter cabinet's parameter debugging and start / stop control, which heavily relies on on-site operation and requires maintenance personnel to be physically present, is transformed into a more efficient maintenance method of "remote start / stop control and remote parameter adjustment." The remote control mode of "digital commissioning" supports remote start and stop functions. External control terminals (such as mobile APPs and PC monitoring platforms) can send start and stop commands to the control module via 4G network and RS485 interface. The first relay output normally open contact of the control module is connected in parallel to the start circuit of the frequency converter cabinet, and the second normally closed contact is connected in series to the stop circuit, realizing direct control of the frequency converter cabinet by remote commands. The 4G communication module supports remote writing of the configuration parameters of the control module (such as start and stop logic thresholds, signal filtering coefficients, etc.) via RS485 interface, avoiding the problem of repeated on-site operations due to parameter adjustments. This design transforms the traditional "one person on-site for each commissioning" mode into "remote real-time operation," significantly reducing the time cost of operation and maintenance personnel. Based on the remote control box of this application, the control module uploads status signals to the external control terminal in real time through the 4G communication module, realizing millisecond-level synchronization between "equipment status and control center." Operators can see the status of the frequency converter cabinet equipment anytime and anywhere, greatly improving operation and maintenance efficiency. Furthermore, the wide-voltage power supply module enhances environmental adaptability, ensures system reliability, and effectively avoids problems such as voltage fluctuations (e.g., AC165V low voltage or AC480V overvoltage) and surge interference that exist in the complex industrial field power supply environment.

[0006] Preferably, it also includes a first flow transmitter and a second flow transmitter; the control module is provided with an RS485 communication terminal for connecting the 4G communication module; the first flow transmitter and the second flow transmitter are respectively connected to the RS485 communication terminal through a 24V power supply line and a signal line.

[0007] By adopting the above technical solution, the first flow transmitter and the second flow transmitter are connected to the control module through a 24V power supply line and an RS485 signal line, respectively, which supports the simultaneous monitoring of two fluid flow data, such as liquid flow and gas flow, and provides multi-parameter acquisition capability.

[0008] Preferably, the system further includes a first pressure transmitter and a second pressure transmitter; the control module also includes two analog input terminals; the first pressure transmitter and the second pressure transmitter are respectively connected to the DC power output terminal of the power module via a 24V power supply line, and the first pressure transmitter and the second pressure transmitter are respectively connected to the two analog input terminals of the control module via signal lines.

[0009] By adopting the above technical solution, this application constructs a high-precision pressure monitoring method through precise docking of analog input terminals and pressure transmitters; the 24V power supply lines of the first pressure transmitter and the second pressure transmitter are independently connected to the 24V+ / - terminals of the control module, and the signal lines are separately connected to the AI1 / AI2 analog input channels, effectively avoiding signal interference caused by multiple devices sharing the same power supply.

[0010] Preferably, the DC power output terminals include a 24V+ power output terminal and a 24V- power output terminal; the 24V+ and 24V- power supply lines of the first pressure transmitter are respectively connected to the 24V+ power output terminal and the 24V- power output terminal; the signal line of the first pressure transmitter is connected to a first analog input terminal; the 24V+ and 24V- power supply lines of the second pressure transmitter are respectively connected to the 24V+ power output terminal and the 24V- power output terminal; and the signal line of the second pressure transmitter is connected to a second analog input terminal.

[0011] By adopting the above technical solution, the 24V+ / - DC power supply is connected to the two pressure transmitters through independent terminals, avoiding voltage fluctuation interference caused by multiple devices sharing the power supply, and improving the power supply stability and independence of each pressure transmitter.

[0012] Preferably, two frequency converter cabinets are provided, and two pairs of switch relay output terminals are provided. Each pair of switch relay output terminals includes a normally open contact connected in parallel to the start circuit of the frequency converter cabinet and a normally closed contact connected in series to the stop circuit of the frequency converter cabinet; the two frequency converter cabinets are configured one-to-one with the two pairs of switch relay output terminals.

[0013] By adopting the above technical solution, for typical application scenarios of two frequency converter cabinets, the control module is configured with two pairs of relay output terminals; through one-to-one independent control, centralized management and control of the two frequency converter cabinets are realized, and fault isolation design between the two frequency converter cabinets can also be realized; through the passive switching characteristics of relay contacts, energy saving and consumption reduction technical effects can also be achieved.

[0014] Preferably, the control module uses an industrial-grade ARM Cortex-M3 processor with a built-in data storage unit and watchdog circuit.

[0015] By adopting the above technical solution, the industrial-grade ARM Cortex-M3 processor (80MHz main frequency, 128KB Flash) supports floating-point operations and real-time multi-task scheduling, meeting the high-speed control requirements of frequency converter cabinets.

[0016] Preferably, the communication module uses an MD620 signal acquisition device.

[0017] By adopting the above technical solutions, the MD620 4G RTU module supports TCP / IP over 4G VPN tunnels and is compatible with multiple protocols such as Modbus / RTU, MQTT, and OPC UA. Through a protocol conversion gateway, seamless integration with various controllers can be achieved, improving the communication protocol compatibility of the remote control box.

[0018] Preferably, the control module or external control terminal receives start control commands and stop control commands to the frequency converter cabinet through the output terminals of the switch relays. The frequency converter cabinet generates a start control signal based on the start control command, triggering the normally open contact of the first relay output to close, and the frequency converter cabinet starts running. The frequency converter cabinet generates a stop control signal based on the stop control command, triggering the normally closed contact of the second relay output to open, and the frequency converter cabinet stops running.

[0019] By adopting the above technical solution, the switch relay output terminals of the control module adopt a "non-intrusive" design: the normally open contact of the first relay output is connected in parallel to the original start button circuit of the frequency converter cabinet. When the remote start command is triggered, the normally closed contact closes, forming an "OR" logic with the local button, without affecting the physical button operation of the original start function; the normally closed contact of the second relay output is connected in series to the original stop button circuit of the frequency converter cabinet. When the remote stop command is triggered, the normally closed contact opens, forming an "AND" logic with the local button, ensuring that the machine can still be forcibly stopped by the local button in an emergency. This design not only realizes the superposition of remote control, but also retains the original local operation function of the frequency converter cabinet, avoiding the control logic confusion caused by the modification.

[0020] Preferably, the enclosure is an IP66 protection-rated shell with an anti-corrosion coating sprayed on the surface.

[0021] By adopting the above technical solution, the IP66 protective enclosure is made of anodized aluminum material and coated with polytetrafluoroethylene anti-corrosion coating, which helps to extend the protection life of the enclosure.

[0022] In summary, this application includes at least one of the following beneficial technical effects: 1. A wide-voltage AC165~480V power supply module is adopted to avoid component damage and control failure due to unstable power supply. This application integrates a remote control box with 4G and control modules, transforming the traditional inverter cabinet's reliance on on-site debugging and start / stop to a remote operation: the external control terminal sends commands via 4G / RS485, and the control module contacts connect in parallel / series to the inverter cabinet circuit to achieve remote start / stop. Debugging parameters can be written remotely or locally. Simultaneously, the control module transmits status in real time via 4G, achieving equipment status synchronization, allowing maintenance personnel to view the status at any time. This design improves maintenance efficiency, reduces time costs, and enhances environmental adaptability with its wide voltage range. 2. The switch relay output terminals of the control module adopt a "non-intrusive" design: the normally open contact of the first relay output is connected in parallel to the original start button circuit of the frequency converter cabinet. When the remote start command is triggered, the normally closed contact closes, forming an "OR" logic with the local button, without affecting the physical button operation of the original start function; the normally closed contact of the second relay output is connected in series to the original stop button circuit of the frequency converter cabinet. When the remote stop command is triggered, the normally closed contact opens, forming an "AND" logic with the local button, ensuring that the machine can still be forcibly stopped through the local button in an emergency. This design not only realizes the superposition of remote control, but also retains the original local operation function of the frequency converter cabinet, avoiding the confusion of control logic caused by the modification. Attached Figure Description

[0023] Figure 1 This is an overall appearance structure diagram of a remote control box based on 4G communication from two perspectives according to an embodiment of this application; Figure 2 This is a schematic diagram of the connection control principle of the power module and the 4G communication module in a remote control box based on 4G communication according to an embodiment of this application; Figure 3 This is a schematic diagram of the connection control principle of the 4G communication module and the control module in a remote control box based on 4G communication according to an embodiment of this application; Figure 4 This is a wiring diagram of a control module, a first flow transmitter, a second flow transmitter, a first pressure transmitter, and a second pressure transmitter in a remote control box based on 4G communication according to an embodiment of this application. Detailed Implementation

[0024] The following is in conjunction with the appendix Figure 1-4 This application will be described in further detail.

[0025] This application discloses a remote control box based on 4G communication. The remote control box based on 4G communication in this embodiment adopts a wall-mounted design and is installed within the inverter cabinet. (Refer to...) Figures 1 to 4The remote control box based on 4G communication includes a box body, a power supply module, a 4G communication module, a control module, a first flow transmitter, a second flow transmitter, a first pressure transmitter, and a second pressure transmitter. This embodiment illustrates the remote control principle using the connection lines between two frequency converter cabinets in the remote control box. The power supply module, 4G communication module, and control module are located within the box body (…). Figure 1 (Not shown in the image).

[0026] Reference Figure 1 The enclosure is made of cast aluminum with an IP66 protection rating. Cast aluminum is highly corrosion-resistant, suitable for outdoor or industrial environments, and also offers excellent heat dissipation. The surface of the enclosure is coated with an anti-corrosion coating. For example, such as... Figure 1 As shown, the dimensions of the enclosure are 320X200X90mm, but in practical applications, it is not limited to this specification.

[0027] Reference Figures 2 to 4 The power supply module is an AC165~480V wide voltage input module. Figure 2 The power supply module is marked with "P" and can use a WDR60 / 120 / 240 / 480-24 model switching power supply; the output power is DC 24V / 2.1A. The power supply module also needs to be connected to an NXB-63 D25 model miniature circuit breaker. Figure 2 The power supply module is marked with QF to provide short-circuit protection; a 24V power switch is also provided on the side of the enclosure for switching the power supply on and off; the power supply module can use UK 2.5 type power terminals. Figure 4 The module uses L1 / L2 / N three-phase power input terminals. The control module is equipped with RS485 communication terminals (RS485A and RS485B terminals in the figure) for connecting to the 4G communication module.

[0028] Reference Figure 3 and Figure 4 The control module is equipped with digital input terminals ( Figure 3 DI1 and DI2 terminals) and the output terminals of the digital relay ( Figure 3 and Figure 4 The DO1, DO2, DO3, and DO4 terminals in this embodiment are provided with 4 channels of digital input terminals. Figure 3The terminals are DI1, DI2, DI3, and DI4. In the output terminals of the digital relays, the normally open contact of the first relay output is connected in parallel to the start circuit of the frequency converter cabinet, and the normally closed contact of the second relay output is connected in series to the stop circuit of the frequency converter cabinet, enabling the control module or external control terminal to control the start and stop of the frequency converter cabinet. The operating status signal of the frequency converter cabinet is fed back to the control module through the digital input terminals. The control module uses an industrial-grade ARM Cortex-M3 processor with a built-in data storage unit and watchdog circuit. The communication module uses an MD620 signal acquisition unit. The MD620 signal acquisition unit integrates a 4G Cat.1 module, establishes a VPN encrypted channel with the cloud server via TCP / IP protocol, supports MQTT protocol data transmission, and its RS485 interface follows the Modbus protocol to interact with the control module. External control terminals include smart terminals such as mobile phones and computers.

[0029] The control module also includes two analog input terminals (AI1 and AI2 in the figure). The first and second pressure transmitters are connected to the DC power output terminals of the power module via 24V power supply lines. The DC power output terminals include a 24V+ power output terminal and a 24V- power output terminal. The first and second pressure transmitters are connected to the two analog input terminals of the control module via signal lines. Specifically, the 24V+ and 24V- power supply lines of the first pressure transmitter are connected to the 24V+ and 24V- power output terminals, respectively; the signal line of the first pressure transmitter is connected to the first analog input terminal; the 24V+ and 24V- power supply lines of the second pressure transmitter are connected to the 24V+ and 24V- power output terminals, respectively; the signal line of the second pressure transmitter is connected to the second analog input terminal.

[0030] Reference Figure 3 and Figure 4 There are two frequency converter cabinets, and each cabinet is equipped with one frequency converter pump. Figure 4 Pump 1 and Pump 2 are used to distinguish them. The switch relay output terminals have two pairs. Figure 4 The DO1 and DO2 terminals are a pair and are connected to the first pressure transmitter. Figure 4 Terminals DO3 and DO4 form a pair, connecting to the second pressure transmitter. Each pair of digital relay output terminals includes one normally open contact connected in parallel to the start circuit of the frequency converter cabinet and one normally closed contact connected in series to the stop circuit of the frequency converter cabinet; two frequency converter cabinets are configured one-to-one with two pairs of digital relay output terminals. That is, each pair of relay output terminals (DO1-DO2, DO3-DO4) independently controls one frequency converter cabinet, and the two pairs of terminals together realize the start and stop control of the two frequency converter cabinets. Figure 4As shown, the DO1 terminal is connected in parallel with the start button of the variable frequency pump 1 in the variable frequency cabinet, and the DO2 terminal is connected in series with the stop button of the variable frequency pump 1 in the variable frequency cabinet; the DO3 terminal is connected in parallel with the start button of the variable frequency pump 2 in the variable frequency cabinet, and the DO4 terminal is connected in series with the stop button of the variable frequency pump 2 in the variable frequency cabinet.

[0031] The control module or external control terminal receives start and stop control commands from the inverter cabinet via the output terminals of the digital relays. The inverter cabinet generates a start control signal based on the start control command, triggering the normally open contact of the first relay to close, thus starting operation. Similarly, the inverter cabinet generates a stop control signal based on the stop control command, triggering the normally closed contact of the second relay to open, thus stopping operation. The normally open contact of the first relay is shown below. Figure 4 In the first case, DO1 COM and DO3 COM are the normally closed contacts of the second relay, such as DO2 COM and DO4 COM.

[0032] The implementation principle of a remote control box based on 4G communication in this application embodiment is as follows: The remote control box's control module has four on / off relay outputs, capable of controlling the start and stop of two frequency converter cabinets. One relay output is used for start control, with its normally open contact connected in series to the start circuit of the frequency converter cabinet. This allows the cabinet to be started via the start button, or via a mobile phone or PC (remote control terminal). The other relay output is used for stop control, with its normally closed contact connected in series to the stop circuit of the frequency converter cabinet. This allows the cabinet to be stopped via the stop button, or via a mobile phone or PC.

[0033] Furthermore, the remote control box's control module has four channels of switch input acquisition. Remote online monitoring can be achieved by directly connecting the operating status switch signals of the frequency converter cabinet on site to the switch input terminals of the control module.

[0034] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A remote control box based on 4G communication, characterized in that, The remote control box, located within the inverter cabinet, includes a cabinet, a power supply module, a 4G communication module, and a control module. The power supply module, 4G communication module, and control module are housed within the cabinet. The 4G communication module connects to an external control terminal via an RS485 interface. The power supply module is an AC165~480V wide voltage input module. The control module has digital input terminals and digital relay output terminals. In the digital relay output terminals, the normally open contact of the first relay output is connected in parallel to the inverter cabinet's start circuit, and the normally closed contact of the second relay output is connected in series to the inverter cabinet's stop circuit, enabling the control module or external control terminal to control the start and stop of the inverter cabinet. The inverter cabinet's operating status signal is fed back to the control module via the digital input terminals.

2. The remote control box based on 4G communication according to claim 1, characterized in that, It also includes a first flow transmitter and a second flow transmitter; the control module is provided with an RS485 communication terminal for connecting to the 4G communication module; the first flow transmitter and the second flow transmitter are respectively connected to the RS485 communication terminal through a 24V power supply line and a signal line.

3. The remote control box based on 4G communication according to claim 1, characterized in that, It also includes a first pressure transmitter and a second pressure transmitter; the control module also includes two analog input terminals; the first pressure transmitter and the second pressure transmitter are respectively connected to the DC power output terminal of the power module through a 24V power supply line, and the first pressure transmitter and the second pressure transmitter are respectively connected to the two analog input terminals of the control module through signal lines.

4. The remote control box based on 4G communication according to claim 3, characterized in that, The DC power output terminals include a 24V+ power output terminal and a 24V- power output terminal; the 24V+ and 24V- power supply lines of the first pressure transmitter are respectively connected to the 24V+ power output terminal and the 24V- power output terminal; the signal line of the first pressure transmitter is connected to a first analog input terminal; the 24V+ and 24V- power supply lines of the second pressure transmitter are respectively connected to the 24V+ power output terminal and the 24V- power output terminal; the signal line of the second pressure transmitter is connected to a second analog input terminal.

5. The remote control box based on 4G communication according to claim 3, characterized in that, Two frequency converter cabinets are provided, and two pairs of switch relay output terminals are provided. Each pair of switch relay output terminals includes a normally open contact connected in parallel to the start circuit of the frequency converter cabinet and a normally closed contact connected in series to the stop circuit of the frequency converter cabinet. The two frequency converter cabinets are configured one-to-one with the two pairs of switch relay output terminals.

6. The remote control box based on 4G communication according to claim 1, characterized in that, The control module uses an industrial-grade ARM Cortex-M3 processor and has a built-in data storage unit and watchdog circuit.

7. The remote control box based on 4G communication according to claim 1, characterized in that, The communication module uses an MD620 signal acquisition unit.

8. The remote control box based on 4G communication according to claim 5, characterized in that, The control module or external control terminal receives start control commands and stop control commands from the output terminals of the switch relays and sends them to the frequency converter cabinet. The frequency converter cabinet generates a start control signal based on the start control command, which triggers the normally open contact of the first relay output to close, and the frequency converter cabinet starts running. The frequency converter cabinet generates a stop control signal based on the stop control command, which triggers the normally closed contact of the second relay output to open, and the frequency converter cabinet stops running.

9. The remote control box based on 4G communication according to claim 1, characterized in that, The enclosure is made of IP66 protection level material and has an anti-corrosion coating on the surface.

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