An integrated retractable intelligent sootblowing controller

Abstract

The utility model discloses an integrated telescopic intelligent soot blower controller relates to industrial equipment control technical field. The controller includes power module, control module, motor detection circuit, input conversion circuit, motor modulation circuit, remote control communication circuit, motor positive and negative rotation output circuit, state output circuit and monitoring circuit. Power module is each module power supply, and control module is based on singlechip, and receives the current signal of motor detection circuit, the pressure and temperature signal of monitoring circuit and the remote signal of remote control communication circuit, realizes motor current regulation and control through motor modulation circuit, controls motor operation direction through motor positive and negative rotation output circuit, and the equipment state is fed back by state output circuit with switch signal amount simultaneously. The controller replaces traditional hardwiring through integrated circuit, integrates control and protection function, supports remote management and control and parameter modification, and the operation efficiency of soot blower and maintenance convenience are improved greatly.

Description

Technical Field

[0001] This utility model relates to the field of kitchen utensil cleaning equipment technology, and in particular to an integrated telescopic intelligent dust blowing controller. Background Technology

[0002] In industries such as power, chemical, and metallurgy, large thermal equipment such as boilers and heat exchangers easily accumulate dust, slag, and other contaminants on their heating surfaces during long-term operation. This leads to a significant decrease in heat exchange efficiency, increasing energy consumption and potentially causing safety hazards such as overheating and corrosion. Therefore, soot blowers are needed to regularly remove accumulated ash and ensure stable equipment operation. Reliable control and safety protection of soot blowers are crucial for ensuring efficient operation and preventing equipment damage, while the design of control and protection circuits directly determines the operating performance and ease of maintenance of the soot blower.

[0003] Telescopic soot blower structure as follows Figure 10 As shown, the sootblower housing contains a telescopic motor, which drives the telescopic rod to extend and retract in both forward and reverse directions. Figure 11 and 12 As shown, the control system of a traditional sootblower relies on the physical wiring of hardware circuits. Specifically, technicians must connect various components such as circuit breakers, contactors, relays, limit switches, and sensors one by one using wires according to the design drawings, forming independent motor forward / reverse control circuits, overload protection circuits, and pressure / temperature monitoring circuits. This hard-wiring-based control mode has many unavoidable drawbacks in practical applications: Firstly, the cost of functional adjustment and maintenance is extremely high. When the control logic of the sootblower needs to be changed in an industrial setting (such as adjusting the motor start-stop sequence or changing the protection threshold triggering conditions), the original wiring connections must be removed, the wiring paths of the components must be replanned, and physical assembly must be performed. This process not only consumes a lot of manpower and time, but also places stringent demands on the professionalism of the construction personnel—they must have a precise understanding of circuit principles, component characteristics, and wiring specifications. Once wiring is incorrect, it can easily lead to control failure, equipment short circuits, or even safety accidents.

[0004] Secondly, the control and protection functions are fragmented and have low integration. In traditional solutions, the motor drive, overload protection, steam pressure monitoring, and steam temperature control functions of the sootblower rely on their own independent hardware circuits, lacking an effective coordination mechanism between these circuits. For example, when the motor operating current exceeds the safety threshold, the overload protection circuit needs to trigger a shutdown command through an independent relay. However, this command cannot be directly linked to the pressure and temperature monitoring circuits, which may result in the sootblower failing to perform a timely reversal reset operation after shutdown, increasing the risk of equipment jamming. At the same time, the fragmented circuit design also leads to a cluttered layout of equipment on site, significantly increasing the difficulty of subsequent troubleshooting and maintenance.

[0005] Third, the level of intelligence is insufficient, and remote control capabilities are lacking. The control of traditional sootblowers mainly relies on on-site manual operation, such as starting / stopping the motor via local buttons and manually adjusting the threshold of protection devices, which cannot achieve remote monitoring and centralized management. For the coordinated operation of multiple sootblowers in large industrial scenarios, operators need to inspect and debug each one on-site, which is not only inefficient but also makes it difficult to obtain the operating parameters (such as motor current, steam pressure, and temperature) and fault status of each sootblower in real time. This results in low transparency of equipment operating status, making it impossible to predict potential faults in a timely manner and affecting the stability of the overall production process.

[0006] Fourth, the signal transmission and parameter adjustment are inflexible. In traditional solutions, the operating parameters of the sootblower (such as current protection threshold, pressure upper limit, and temperature lower limit) need to be adjusted manually on-site by adjusting potentiometers or replacing components, and cannot be modified remotely in real time. At the same time, the signal transmission of various monitoring parameters (such as motor three-phase current, steam pressure, and temperature) mostly relies on analog hard-wired connections, and the signals are easily affected by on-site electromagnetic interference, which leads to a decrease in the accuracy of monitoring data, thereby affecting the triggering accuracy of the protection circuit and increasing the risk of equipment malfunction or failure.

[0007] In summary, traditional sootblower control schemes, relying on hard-wired physical circuits, suffer from problems such as cumbersome function adjustments, low integration, insufficient intelligence, and poor parameter control flexibility, making them unable to meet the demands of modern industrial production for efficient equipment operation, convenient maintenance, and remote control. Therefore, developing a sootblower controller that integrates multiple control and protection circuits, replaces hard-wired wiring with software logic, and possesses intelligent communication and remote control capabilities has become an urgent technical problem to be solved in the field of industrial equipment control. Summary of the Invention

[0008] The technical problem to be solved by this utility model is to provide an integrated telescopic intelligent soot blowing controller to solve the problems of cumbersome control and adjustment and low integration of soot blowers in the prior art.

[0009] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: An integrated telescopic intelligent soot blowing controller includes a control module, an input conversion circuit, a motor modulation circuit, a remote control communication circuit, a motor forward / reverse output circuit, and a status output circuit. The input conversion circuit collects key control signals and status signals and sends them to the control module. The control module outputs control signals to the motor modulation circuit, the motor forward / reverse output circuit, and the status output circuit to control the motor current, the motor forward / reverse direction, and the status signal output, respectively. The remote control communication circuit converts remote control signals through a communication chip and sends them to the communication terminal of the control module.

[0010] The input terminal of the aforementioned control module receives the current signals of each phase of the telescopic motor detected by the motor detection circuit.

[0011] The input terminal of the aforementioned control module receives the soot blowing pressure and temperature signals monitored by the monitoring circuit.

[0012] The aforementioned control module, motor detection circuit, input conversion circuit, motor modulation circuit, remote control communication circuit, motor forward and reverse rotation output circuit, status output circuit, and monitoring circuit are powered by the power supply module, which converts the three-phase AC power into DC power.

[0013] In the motor detection circuit described above, the current transformer monitors the current signals of each phase of the telescopic motor and steps them down into AC signals ACIN_1, ACIN_2 and ACIN_3. After signal isolation and amplification, the AC signals ACIN_1, ACIN_2 and ACIN_3 are converted into DC digital signals ACAD_1, ACAD_2 and ACAD_3 and sent to the input terminal of the control module.

[0014] In the aforementioned input conversion circuit, the key control signals and status signals are first isolated by optocouplers and then sent to the register chip. The register chip converts the collected signals into parallel signals and transmits them to the input terminal of the control module. The key control signals include remote / local key signals, local start key signals, local back key signals, and remote start key signals and remote back key signals transmitted from a distance. The status signals include overload reset signals, normally open front limit signals, normally closed front limit signals, normally open rear limit signals, normally closed rear limit signals, and low pressure signals.

[0015] The aforementioned motor modulation circuit converts the motor PWM modulation voltage signal sent from the output of the control module into a current signal through a conversion chip and then sends it to the telescopic motor. The motor is controlled by modulating the current.

[0016] The aforementioned status output circuit converts the status output signal into a switching signal quantity via optical coupling.

[0017] The integrated telescopic intelligent soot blowing controller provided by this utility model has the following beneficial effects: 1. Simplify control processes and reduce maintenance costs. This invention abandons the traditional control mode of soot blowers that relies on hard-wired connections of components. Instead, it uses software logic in the control module to achieve functions such as motor forward and reverse rotation, current regulation, and pressure / temperature protection. When adjustments to the control logic are needed (such as modifying protection thresholds or optimizing motor start-stop timing), there is no need to remove old wires or reassemble hardware circuits. The adjustments can be made simply by updating the code via remote communication or local programming. This not only reduces on-site construction work by more than 90% but also reduces reliance on the professional skills of construction personnel. It avoids safety hazards such as control failures and equipment short circuits caused by wiring errors, and significantly reduces the manpower and time costs of functional adjustments and subsequent maintenance.

[0018] 2. Enhance integration and strengthen collaborative protection capabilities. The controller integrates functional modules such as motor detection, pressure monitoring, temperature monitoring, remote communication, and status output into one unit, with each module working in tandem through the control module. For example, when the motor detection circuit detects a current overload, or when the monitoring circuit detects that the pressure exceeds the upper limit or the temperature is below the threshold, the control module can immediately trigger the motor forward / reverse output circuit to switch to the reverse phase sequence, driving the sootblower to retreat to the rear limit stop. At the same time, the status output circuit provides feedback on the fault status. Compared to traditional distributed hardware loops, this avoids problems such as "inability to reset after shutdown" and "delayed fault response" caused by the independent operation of each protection function. The protection logic response time is shortened to the millisecond level, significantly improving the operational safety of the sootblower and reducing the risk of equipment jamming and damage.

[0019] 3. Enable intelligent remote management and control, adaptable to large-scale applications. The remote control communication circuit is built on the Modbus RTU protocol to construct a communication network, supporting networked linkage of multiple sootblowers. Operators can obtain real-time motor current, steam pressure, temperature, and operating status (forward / reverse / limit switch) of each sootblower through a remote terminal, and remotely modify protection thresholds such as current, pressure, and temperature, eliminating the need for on-site inspection and debugging. Taking a large power plant boiler as an example, the traditional solution requires 3-5 operators to manage 20 sootblowers on-site. This controller allows one operator to complete all management and control through the central control system, improving work efficiency by more than 60%. At the same time, the remote data acquisition and status feedback functions can realize early fault prediction and accurate location, reduce unplanned downtime, and ensure the stability of industrial production processes.

[0020] 4. Optimize signal processing to ensure operational stability In the signal input and output stages, the input conversion circuit eliminates the influence of on-site electromagnetic interference on the button control signals and status signals through optocoupler isolation. The motor detection circuit converts the AC current signal into a stable DC digital signal through signal isolation and amplification. The status output circuit converts the signal into a reliable switching signal through optocoupler. Compared with the problem of traditional analog hard-wired signals being susceptible to interference, the signal transmission accuracy of this controller is improved to ±0.5%, and the protection threshold trigger accuracy reaches 100%. It effectively avoids equipment malfunction or protection failure caused by signal distortion, and is especially suitable for industrial scenarios with strong electromagnetic interference such as power and chemical industries, ensuring the long-term stable operation of the sootblower.

[0021] 5. Highly adaptable and compatible with various scenarios. The controller supports dual operation modes: remote and local. When the DDPIN_1 input signal is "1", it automatically switches to local control to meet emergency on-site operation needs. When receiving remote signals via the remote control communication circuit, it enables unattended automated control, adapting to different operational preferences in various industrial scenarios. Simultaneously, the motor modulation circuit precisely controls the motor current using PWM modulation technology, adaptable to telescopic motors of varying power (0.5-5kW). The monitoring circuit supports a wide range of detection: 0-10A current, 0-5MPa pressure, and 0-500℃ temperature. This eliminates the need to redesign control loops for different sootblower models, significantly improving the product's versatility and adaptability. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is the circuit diagram of the power module of this utility model; Figure 2 This is the circuit diagram of the control module of this utility model; Figure 3 This is a schematic diagram of the motor detection circuit of this utility model; Figure 4 This is a schematic diagram of the input conversion circuit of this utility model; Figure 5 This is a schematic diagram of the motor modulation circuit of this utility model; Figure 6 This is a schematic diagram of the remote control communication circuit of this utility model; Figure 7 This is a schematic diagram of the forward and reverse rotation output circuit of the motor according to this utility model; Figure 8 This is a schematic diagram of the status output circuit of this utility model; Figure 9 This is a schematic diagram of the monitoring circuit of this utility model; Figure 10 This is a schematic diagram of the soot blower of this utility model; Figure 11 Wiring diagram for an existing telescopic sootblower motor; Figure 12 This is a schematic diagram of the motor control principle for an existing telescopic sootblower.

[0023] In the diagram: Power module 1, Control module 2, Motor detection circuit 3, Input conversion circuit 4, Motor modulation circuit 5, Remote control communication circuit 6, Motor forward and reverse rotation output circuit 7, Status output circuit 8, Monitoring circuit 9, Soot blower housing 10, Soot blowing telescopic rod 11. Detailed Implementation

[0024] The technical solution of this utility model will be further described below with reference to the accompanying drawings and embodiments.

[0025] like Figure 1-9 As shown, an integrated telescopic intelligent soot blowing controller includes a control module 2, an input conversion circuit 4, a motor modulation circuit 5, a remote control communication circuit 6, a motor forward / reverse output circuit 7, and a status output circuit 8. The input conversion circuit 4 collects the button control signals and status signals and sends them to the control module 2. The control module 2 outputs control signals to the motor modulation circuit 5, the motor forward / reverse output circuit 7, and the status output circuit 8 to control the motor current, the motor forward / reverse rotation, and the status signal output, respectively. The remote control communication circuit 6 converts the remote control signals through a communication chip and sends them to the communication terminal of the control module 2.

[0026] like Figure 2 As shown, the control module 2 uses a single-chip microcomputer STC8H3K64S4 to receive and send corresponding control signals to control the extension and retraction movements and monitor the status output of the soot blower, receiving button inputs, status signals, and remote control signals.

[0027] The input terminal of the aforementioned control module 2 receives the current signals of each phase of the telescopic motor detected by the motor detection circuit 3.

[0028] The input terminal of the aforementioned control module 2 receives the soot blowing pressure and temperature signals monitored by the monitoring circuit 9.

[0029] like Figure 2 and 9 As shown, Figure 9 The medium pressure detection signal ZLDYIN+_1 and temperature detection signal ZLDYIN+_2 are processed by the arc extinguishing resistor-capacitor combination and the anti-reverse diode, and then output as signals ZLDY_1 and ZLDY_2 to the input terminal of control module 2.

[0030] The control module 2, motor detection circuit 3, input conversion circuit 4, motor modulation circuit 5, remote control communication circuit 6, motor forward and reverse rotation output circuit 7, status output circuit 8, and monitoring circuit 9 mentioned above are powered by the power supply module 1 converting the three-phase AC power into DC power.

[0031] like Figure 1 As shown, the single-phase 380V inputs LA and LB are input to the DC 24V power supply D2_1, which is converted into a 24V DC power supply. The 24V DC power supply is then converted into a 5V DC power supply by the 5V regulated power supply D10_1.

[0032] In the motor detection circuit 3 described above, the current transformer monitors the current signals of each phase of the telescopic motor and steps them down into AC signals ACIN_1, ACIN_2 and ACIN_3. After signal isolation and amplification, the AC signals ACIN_1, ACIN_2 and ACIN_3 are converted into DC digital signals ACAD_1, ACAD_2 and ACAD_3 and sent to the input terminal of the control module 2.

[0033] like Figure 3 As shown in the diagram, taking the current of one phase motor as an example, the current transformer steps down the A-phase current to ACIN_1, and together with the grounding signal, it is amplified by amplifier L26_1 and then input to capacitor L15_1. The AC signal is isolated and converted by the capacitor's DC blocking and AC passing function and then sent to the secondary amplifier L25_1. The amplified signal ACAD_1 is sent to the input terminal of control module 2. Terminals 2 and 3 of amplifier L26_1 are the input terminals, and the output amplification terminal is 6. Terminals 5 and 6 of secondary amplifier L25_1 are the input terminals, and the output amplification terminal is 7.

[0034] The key control signals and status signals in the input conversion circuit 4 are first isolated by optocouplers and then sent to the register chip. The register chip converts the collected signals into parallel signals and sends them to the input terminal of the control module 2. The key control signals include remote / local key signals, local start key signals, local back key signals, and remote start key signals and remote back key signals transmitted from a distance. The status signals include overload reset signals, front limit normally open signals, front limit normally closed signals, rear limit normally open signals, rear limit normally closed signals, and low pressure signals.

[0035] like Figure 4As shown, when the DDPIN_1 input signal is "1", the signal is converted to DDPXH_1 by the optocoupler H2_1 and then connected to pin D0_1 of the register chip H6_1. The register chip H6_1 converts the signal into a parallel signal, which is then sent to pins P4.2, P4.3, and P4.0 of the control module 2 via pins 1, 2, and 9 of PC, CP, and Q7_1. Upon receiving the signal, the control module 2 automatically switches the operation permission to "local". Similarly, when the DDPIN_2 input signal is "1", the soot blowing starts locally. The controller controls the output terminal signals JDQ_CF1-JDQ_CF5, that is, through the motor forward / reverse output circuit 7, the telescopic motor is in the forward rotation wiring state, and the output signal DL_PWM_1-... DL_PWM_3 controls the motor current. The soot blowing telescopic rod 11 moves from the rear limit to the front limit. When it reaches the front limit, DDPXH_7 and 8 switch states. The control module 2 receives the front limit signal and stops moving. Other backward and stop movements are similar.

[0036] like Figure 7 As shown, in the motor forward and reverse output circuit 7, five power relays K7_1 to K7_5 are used to switch the phase sequence. By swapping the phase sequence of any two phases in the three-phase power supply, the rotation direction of the motor can be changed.

[0037] The motor modulation circuit 5 described above converts the motor PWM modulation voltage signal sent by the output of the control module 2 into a current signal through a conversion chip and then sends it to the telescopic motor. The motor is controlled by modulating the current.

[0038] like Figure 5 As shown, the control module 2 inputs the PWM modulation signal DL_PWM_1 and converts it into the current signal DL_OUT1 via the conversion chip XTR111AIDGQR.

[0039] The aforementioned status output circuit 8 converts the status output signal into a switching signal quantity through optical coupling.

[0040] like Figure 8 As shown, remote / local, power normal, overload signal, moving forward, moving backward, low pressure, front limit and back limit signals are output via digital signals.

Claims

1. An integrated telescopic intelligent soot blowing controller, characterized in that: It includes a control module (2), an input conversion circuit (4), a motor modulation circuit (5), a remote control communication circuit (6), a motor forward and reverse rotation output circuit (7), and a status output circuit (8). The input conversion circuit (4) collects the key control signals and status signals and sends them to the control module (2). The control module (2) outputs control signals to the motor modulation circuit (5), the motor forward and reverse rotation output circuit (7), and the status output circuit (8) to control the motor current, the motor forward and reverse rotation, and the status signal output, respectively. The remote control communication circuit (6) converts the remote control signals through the communication chip and sends them to the communication terminal of the control module (2).

2. The integrated telescopic intelligent soot blowing controller according to claim 1, characterized in that, The input terminal of the control module (2) receives the current signals of each phase of the telescopic motor detected by the motor detection circuit (3).

3. The integrated telescopic intelligent soot blowing controller according to claim 2, characterized in that, The input terminal of the control module (2) receives the soot blowing pressure and temperature signals monitored by the monitoring circuit (9).

4. The integrated telescopic intelligent soot blowing controller according to claim 3, characterized in that, The control module (2), motor detection circuit (3), input conversion circuit (4), motor modulation circuit (5), remote control communication circuit (6), motor forward and reverse rotation output circuit (7), status output circuit (8) and monitoring circuit (9) are powered by the power supply module (1) converting the three-phase AC power into DC power.

5. An integrated telescopic intelligent soot blowing controller according to claim 2, characterized in that, In the motor detection circuit (3), the current transformer monitors the current signals of each phase of the telescopic motor and reduces them to AC signals ACIN_1, ACIN_2 and ACIN_3. After signal isolation and amplification, the AC signals ACIN_1, ACIN_2 and ACIN_3 are converted into DC digital signals ACAD_1, ACAD_2 and ACAD_3 and sent to the input terminal of the control module (2).

6. The integrated telescopic intelligent soot blowing controller according to claim 1, characterized in that, The key control signal and status signal in the input conversion circuit (4) are first isolated by optocouplers and then sent to the register chip. The register chip converts the collected signals into parallel signals and sends them to the input terminal of the control module (2). The key control signal includes remote / local key signal, local start key signal, local back key signal, and remote start key signal and remote back key signal transmitted from the remote location. The status signal includes overload reset signal, front limit normally open signal, front limit normally closed signal, rear limit normally open signal, rear limit normally closed signal, and low pressure signal.

7. The integrated telescopic intelligent soot blowing controller according to claim 1, characterized in that, The motor modulation circuit (5) converts the motor PWM modulation voltage signal sent by the output terminal of the control module (2) into a current signal through a conversion chip and then sends it to the telescopic motor. The motor is controlled by modulating the current.

8. The integrated telescopic intelligent soot blowing controller according to claim 1, characterized in that, The aforementioned status output circuit (8) converts the status output signal into a switching signal quantity through optical coupling.

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