A boiler furnace tube leakage 32 channel signal acquisition and I / O control board card

Abstract

The utility model discloses a kind of boiler furnace tube leakage 32 channel signal acquisition and I / O control board card, including signal acquisition control panel, printed circuit is provided on the signal acquisition control panel, signal acquisition control panel is also equipped with PCIe interface, control unit, SCSI connector, communication card slot, multipath relay module, multipath photocoupler module and control card slot, PCIe interface is electrically connected with control unit by printed circuit, control unit is electrically connected with multipath relay module, multipath photocoupler module and communication card slot respectively, multipath relay module and multipath photocoupler module are electrically connected with control card slot respectively, SCSI connector is electrically connected with control unit.Compared with prior art, 32 point signal processing, multipath input and output control function is integrated in single signal acquisition control panel, without occupying multiple PCI card slot, greatly simplifies hardware configuration.

Description

Technical Field

[0001] This utility model relates to a signal acquisition device, and in particular to a 32-channel signal acquisition and I / O control board for boiler tube leakage. Background Technology

[0002] Traditional 32-channel signal acquisition cards and I / O control cards employ a separate design, operating independently and requiring separate insertion into the computer's PCI slots. This occupies two independent PCI slots. Furthermore, the traditional PCI interface itself has significant drawbacks: high power consumption increases overall device energy consumption, and limited transmission speed and response time make it difficult to meet the demands of high-precision, high-speed data acquisition and real-time control. This separate design not only increases hardware procurement costs but also requires more motherboard space during installation, making subsequent inspection, replacement, and maintenance more cumbersome. It significantly reduces the convenience of system deployment and maintenance, making it unsuitable for efficient and compact industrial applications. Utility Model Content

[0003] The purpose of this utility model is to provide a 32-channel signal acquisition and I / O control board for boiler tube leakage. The technical problem to be solved is to integrate 32-point signal acquisition and I / O control into one unit, thereby reducing the number of PCI card slots occupied by the industrial control computer.

[0004] To solve the above problems, this utility model adopts the following technical solution: a 32-channel signal acquisition and I / O control board for boiler tube leakage, including a signal acquisition control board. The signal acquisition control board is provided with printed circuit boards, and also has a PCIe interface, a control unit, a SCSI connector, a communication card slot, multiple relay modules, multiple optocoupler modules, and a control card slot. The PCIe interface is electrically connected to the control unit through the printed circuit boards. The control unit is electrically connected to the multiple relay modules, multiple optocoupler modules, and the communication card slot. The control unit is used to perform digital-to-analog conversion or digital node control on the input signals; and outputs the processed signals directly through the communication card slot or through controlling the multiple relay modules and / or multiple optocoupler modules. The multiple relay modules and multiple optocoupler modules are electrically connected to the control card slot. The SCSI connector is electrically connected to the control unit. The SCSI connector is used to connect to external signal sources and distributed control systems, sending the signals input from the 32 signal sources and distributed control systems to the control unit for processing.

[0005] Furthermore, the 32-channel signal source consists of 32 sensor modules.

[0006] Furthermore, the control unit is an FPGA control unit.

[0007] Furthermore, the SCSI connector is a 68-pin connector.

[0008] Furthermore, the relay module has eight relays.

[0009] Furthermore, the relay module uses a 12V relay.

[0010] Furthermore, the optocoupler module has eight units.

[0011] Furthermore, the optical coupling module employs an optocoupler.

[0012] Furthermore, the control card slot uses a DB37 interface.

[0013] Furthermore, the communication card slot uses a DB37 interface.

[0014] Compared with the prior art, this utility model has the following technical effects:

[0015] 1. Highly Integrated Multifunctional Design: Compared to traditional separate boards that require separate deployment of signal acquisition and I / O control functions, this invention highly integrates core functions such as 32-point signal processing and multi-channel input / output control into a single signal acquisition and control board. This eliminates the need for multiple PCI slots, significantly simplifying hardware configuration. The integrated design not only reduces board size and lowers hardware procurement and deployment costs but also achieves diversified functional coverage. It can simultaneously meet the multi-dimensional needs of boiler tube leakage monitoring, including signal acquisition, data transmission, and command execution, adapting to the compact and efficient application requirements of industrial scenarios.

[0016] 2. Flexible and Expandable Signal Transmission Solution: The board uses a SCSI connector as the core signal transmission interface. This connector features a high-density pin layout and stable signal transmission performance, converting two 37-pin signal connection lines through the control unit. This design ensures simultaneous access and stable transmission of 32 channels of signals while also enabling multi-threaded parallel processing. It can simultaneously respond to the signal acquisition needs of different monitoring points, avoiding data delays caused by congestion on a single channel and improving overall monitoring efficiency.

[0017] 3. Reliable and efficient I / O control capabilities: A specially designed combination architecture of multi-channel relay modules and multi-channel optocoupler modules is employed. The optocoupler modules feature a high isolation voltage of 5000Vrms and a fast response characteristic of ≤10μs, effectively isolating strong and weak electrical interference and ensuring the safety and accuracy of signal transmission. The relay modules support large contact capacities of 10A / 250VAC and 5A / 30VDC, stably executing switching control commands and achieving precise control of external sensors, alarm devices, etc. Together, they construct a stable and reliable I / O control system, meeting the stringent requirements of industrial-grade control. Attached Figure Description

[0018] Figure 1 This is a structural block diagram of the present invention.

[0019] Figure 2 This is a schematic diagram of the signal acquisition and control board of this utility model. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0021] like Figure 1 and Figure 2 As shown, this utility model discloses a 32-channel signal acquisition and I / O control board for boiler tube leakage, including a signal acquisition control board 1. The signal acquisition control board 1 is a PCB circuit board with printed circuits. It is provided with a PCIe interface 2, a control unit 3, a SCSI connector 4, a communication card slot 5, a multi-channel relay module 6, a multi-channel optocoupler module 7, and a control card slot 8.

[0022] in:

[0023] Control unit 3 is used for analog-to-digital conversion of input signals and I / O digital node control. The processed signals are output directly through communication card slot 5 or through multiple relay modules 6 and / or multiple optocoupler modules 7. The input signals are analog signals or I / O digital node signals. Control unit 3 is an FPGA control unit, such as an STM32 microcontroller. Control unit 3 is soldered onto the pads of signal acquisition control board 1 and connected to the module pins through internal wiring of signal acquisition control board 1. This STM32 microcontroller integrates rich peripheral resources and powerful data processing capabilities, serving as the core control hub. Its core functions cover analog-to-digital conversion and digital node control. On one hand, it can receive 0~10V analog signals from 32 sensor modules, accurately converting continuously changing analog signals into discrete digital signals through the built-in analog-to-digital conversion module of control unit 3, with a conversion accuracy of up to 12 bits, ensuring the accuracy of signal acquisition. On the other hand, it can perform logical operations and instruction parsing on the received digital node signals, thereby issuing precise control signals to each execution module to achieve orderly scheduling of the entire monitoring system.

[0024] When the digital node signals of external I / O (digital node signals are divided into output nodes and input nodes; output node signals are commands sent by the furnace tube leakage software control, and input node signals are input signals sent by DCS communication, such as equipment start / stop status, external control commands, etc.) are transmitted to the control unit 3 through the SCSI connector 4 via internal lines, the control unit 3 performs logical operations, priority sorting, and command parsing on the signals. Then, based on the processing results, it outputs corresponding control signals to the multi-channel relay module 6 and / or the multi-channel optocoupler module 7, driving the relay module to turn on or off or the optocoupler module to turn on, and outputs through the control card slot 8, thereby realizing precise control of external devices and completing the complete workflow of "signal input - data processing - command output - equipment control".

[0025] The processed signals are specifically: switching signals and digital signals.

[0026] Switch signals include: a fault alarm switch signal, which controls the relay to activate and trigger an external alarm device (such as an audible and visual alarm) when an abnormal sensor signal or a malfunction is detected; a signal switching switch signal, which allows switching the signal access channel of different sensors according to monitoring needs, enabling rotating monitoring of multiple monitoring points; a self-test control switch signal, which supports the leakage detection system to automatically start the self-test program periodically, and detects the working status of each module by controlling the on / off state of the relay to ensure stable operation of the equipment; and a soot blowing suppression switch signal, which provides precise control of the boiler soot blowing system.

[0027] Digital signal: The input analog signal is converted into a digital signal and then output.

[0028] SCSI (Small Computer System Interface) connector 4 is electrically connected to control unit 3. SCSI connector 4 has a 68-pin connector with gold plating. It is directly soldered to the I / O pins of control unit 3 via dedicated differential signal lines, ensuring strong connection stability and low signal transmission loss. SCSI connector 4 connects to 32 signal sources and the distributed control system (DSC) via data lines to receive analog signals from the 32 signal sources and soot blowing suppression switch signals from the DSC. It then transmits these signals to control unit 3. The 32 signal sources consist of 32 sensor modules, allowing control unit 3 to acquire signals from these sensor modules via the SCSI connector. These sensor modules are sound sensors.

[0029] PCIe interface 2 is electrically connected to control unit 3 and is used to connect the gold-plated contacts of the expansion card to provide power. The PCIe interface consists of gold fingers printed on the signal acquisition control board 1, which are inserted into the host PCIe card slot. The gold fingers are gold-plated and have good conductivity and anti-oxidation properties. They can be directly inserted into the host PCIe card slot to provide 3.3V and 12V voltage to the module.

[0030] In this utility model, the host is a dedicated industrial control computer for furnace tube leakage detection system, generally using the Yanhua 610L model industrial control computer.

[0031] Communication card slot 5 is electrically connected to control unit 3. Control unit 3 converts analog signals into corresponding digital signals and outputs them through communication card slot 5. When analog signals (such as pressure, temperature, vibration, etc.) from sensors #1 to #32 in the boiler tube leakage monitoring scenario are connected to SCSI 68P connector 4 via external cables, the signals are transmitted to control unit via internal circuitry. Control unit performs preliminary filtering and shaping on the signals to remove electromagnetic interference noise from the industrial site. After being converted into digital signals from #1 to #32 via the built-in digital-to-analog converter module in control unit, the signals are output through communication card slot 5. In this utility model, communication card slot 5 adopts a standard DB37 connector to provide a standardized data format for subsequent data processing and analysis.

[0032] The multi-channel relay module 6 is electrically connected to the control unit 3 and the control card slot 8. It is used to output the switch signals sent by the control unit 3 through the control card slot 8. The switch signals are output fault alarm switch, signal switching switch and self-test control switch. The relay module 6 adopts G6K-2F-Y 12V relay. This model of relay has the advantages of small size, fast response speed (switch response time ≤10ms) and large contact capacity (supports 10A / 250VAC, 5A / 30VDC). There are a total of 8 relay modules. They are connected to the control card slot 8 through control signal lines. The connection method is that the 8 relay modules are connected in parallel with the control unit 3 and the control card slot 8. Its main function is to output three types of key switch signals through the control card slot 8: First, a fault alarm switch signal, which controls the relay to activate when the FPGA detects abnormal sensor signals or board malfunctions, triggering an external alarm device (such as an audible and visual alarm) to issue a warning; second, a signal switching switch signal, which can switch the signal access channels of different sensors according to monitoring needs, realizing the rotational monitoring of multiple monitoring points; and third, a self-test control switch signal, which supports the leakage detection system to automatically start the self-test program periodically, and detects the working status of each module by controlling the on and off of the relay, ensuring the stable operation of the equipment.

[0033] The multi-channel optocoupler module 7 is electrically connected to the control unit 3 and the control card slot 8. When the control unit 3 sends a DCS soot blowing suppression switch signal to the multi-channel optocoupler module 7, the optocoupler module 7 outputs the soot blowing suppression switch signal through the control card slot 8. The optocoupler module 7 uses eight TLP521 GB optocouplers, connected in parallel to the control unit 3 and the control card slot 8. This optocoupler features a high isolation voltage of 5000Vrms, low forward voltage drop, and fast switching characteristics (response time ≤5μs), effectively isolating strong and weak electrical signals and suppressing electromagnetic interference in the industrial environment. When the DCS (Distributed Control System) sends a soot blowing suppression switch signal to the control unit 3 via the SCSI connector 4, the control unit 3 sends the signal to the multi-channel optocoupler module 7. The internal LED of the optocoupler conducts, transmitting the signal to the control card slot 8 through optocoupler coupling to output a standardized soot blowing suppression switch signal. This achieves precise control of the boiler soot blowing system and prevents interference with leakage monitoring signals caused by soot blowing operations.

[0034] Control card slot 8 is used for electrical connection with relay module 6 and optocoupler module 7. Relay module 6 and optocoupler module 7, as core execution components, operate in close coordination with control unit 3. When external I / O digital node signals (such as device start / stop status, external control commands, etc.) are connected to the board via SCSI connector 4, they are transmitted to control unit 3 via internal circuitry. Control unit 3 performs logical operations, priority sorting, and command parsing on the signals. Based on the processing results, it outputs corresponding control signals to relay module 6 and / or optocoupler module 7, driving the relay to turn on / off or the optocoupler to conduct. The output is then transmitted through control card slot 8, which uses a standard DB37 connector, enabling precise control of external devices and completing the entire workflow of "signal input - data processing - command output - device control".

[0035] The following detailed explanation uses the STM32 microcontroller as an example: Pins 14-23 (PA0-PA7) of the control unit are connected to the IN pin of one optocoupler module 7, and pins 26-28 and 55-59 (PB0-PB7) of the control unit are connected to the IN pin of one relay module 6, respectively; pins 1-32 of the SCSI connector 4 are connected to pins PC0-PC15, PA8-15, and PB8-15 of the control unit; pins PD0-15 and PE0-15 of the control unit are connected to pins 1-32 of the communication card slot; pin 7 (+3.3V) and pin 8 (GND) of PCIe are connected to pins 49 (VSS-1) and 50 (VDD-1) of the control unit; pin 3 (+12V) and pin 4 (GND) of PCIe are connected to pins 74 (VSS-2) and 75 (VDD-2) of the control unit.

[0036] During operation, the signal acquisition and control board 1 is inserted into the host PCIe slot via PCIe gold fingers 2. When the analog signals #1~#32 from the sensor are sent to the control unit 3 via SCSI connector 4, they are converted into digital signals #1~#32 by the control unit 3 and then transmitted out via communication card slot 5. The I / O digital node signals are sent to the control unit via SCSI connector 4, and then the control unit 3 controls the relay module 6 and / or optocoupler module 7. When any measuring point of the boiler tube leak malfunctions, the fault signal is transmitted to the control unit 2 via SCSI connector 4 for processing, and then the relay module 6 triggers the fault alarm switch via control card slot 8. The signal switching function required by the signal switching board is triggered by the relay module via control card slot. The boiler tube leak detection software has a self-test function. When self-test control is required, the multi-channel relay module triggers the self-test control switch via control card slot. The DCS soot blowing suppression signal is sent to the multi-channel optocoupler module and then triggers the soot blowing suppression switch via control card slot. This realizes the integrated function of signal transmission and input / output control. When the equipment is officially put into operation, the signal acquisition and control board is precisely inserted into the PCIe slot of the industrial control computer using standardized PCIe gold fingers. A stable communication link is established with the industrial control computer system via the high-speed PCIe 3.0x4 bus, providing a high-speed channel for data transmission and command interaction. In the signal acquisition and transmission stage, the analog signals collected by sensors #1 to #32 (covering pressure, temperature, vibration, etc.) in the boiler tube leakage monitoring system are centrally connected to the SCSI connector via dedicated shielded cables and transmitted to the control unit through internal anti-interference circuitry. The control unit activates its built-in 12-bit high-precision ADC conversion module to filter, amplify, and perform digital-to-analog conversion on the analog signals, accurately converting the continuously changing analog signals into standardized #1 to #32 digital signals. These digital signals are then stably transmitted to the industrial control computer system or remote monitoring platform via the communication card slot, providing accurate data support for leakage status analysis.

[0037] In the I / O control execution phase, the digital node signals of external device I / O (such as device start / stop status, external control commands, etc.) are also connected to the board via the SCSI connector. After being transmitted to the control unit, logical operations, priority sorting, and command parsing are performed, and then targeted switching signals are sent to the multi-channel relay module and / or multi-channel optocoupler module. When any measuring point signal of the boiler tube leakage monitoring is abnormal (such as exceeding the preset threshold), the fault signal is sent to the control unit through SCSI connector 4. The control unit quickly identifies the fault information and triggers the fault alarm switch signal, driving the multi-channel relay module to act. The fault alarm switch signal is output through the control card slot, instantly triggering external audible and visual alarms and other devices to remind personnel to handle the situation in a timely manner. For signal switching requirements, the multi-channel relay module responds to the control unit's command and triggers the signal switching switch signal through the control card slot to achieve rapid switching between different sensor channels or monitoring points, adapting to multi-scenario monitoring needs. During host startup or periodic maintenance, a self-test command can be issued. The control unit controls the multi-channel relay module to send a self-test control switch signal through the control card slot, sequentially testing the connectivity and signal transmission performance of each sensor channel to ensure the reliability of equipment operation. Furthermore, when the DCS (Distributed Control System) sends a soot blowing suppression switch signal, the control unit sends the signal to the optocoupler module. After processing with a 5000Vrms high isolation voltage, a standardized soot blowing suppression switch signal is output through the control card slot, precisely controlling the start and stop of the boiler soot blowing system and preventing interference from soot blowing operations to leakage monitoring signals. The entire workflow is tightly integrated and responds rapidly, successfully achieving a high degree of integration between signal acquisition and transmission and input / output control, meeting the needs of efficient monitoring and precise control in industrial scenarios.

[0038] This utility model has the following features: 1. The signal acquisition and control board integrates 32-point signal processing and multi-channel input / output control, realizing the integration and diversification of board functions; 2. By setting communication card slots and signal card slots, two 37-pin signal connection lines can be generated, and 68-pin input can be achieved through SCSI connectors, realizing multi-threaded processing; 3. A multi-channel relay module and a multi-channel optocoupler module are designed to realize multi-channel input / output control.

Claims

1. A 32-channel signal acquisition and I / O control board for boiler tube leakage, comprising a signal acquisition and control board (1), characterized in that: The signal acquisition control board (1) is provided with printed circuit boards. The signal acquisition control board (1) is also provided with a PCIe interface (2), a control unit (3), a SCSI connector (4), a communication card slot (5), a multi-channel relay module (6), a multi-channel optocoupler module (7), and a control card slot (8). The PCIe interface (2) is electrically connected to the control unit (3) through the printed circuit boards. The control unit (3) is electrically connected to the multi-channel relay module (6), the multi-channel optocoupler module (7), and the communication card slot (5), respectively. The control unit (3) is used to process the input signals. The signal is converted from digital to analog or controlled by digital nodes. The processed signal is output directly through the communication card slot (5) or through the control of multiple relay modules (6) and / or multiple optocoupler modules (7). The multiple relay modules (6) and multiple optocoupler modules (7) are electrically connected to the control card slot (8) respectively. The SCSI connector (4) is electrically connected to the control unit (3). The SCSI connector (4) is used to connect external signal sources and distributed control systems, and sends the signals input from the 32 signal sources and distributed control systems to the control unit (3) for processing.

2. The boiler tube leakage 32-channel signal acquisition and I / O control board according to claim 1, characterized in that: The 32-channel signal source consists of 32 sensor modules.

3. The boiler tube leakage 32-channel signal acquisition and I / O control board according to claim 2, characterized in that: The control unit (3) is an FPGA control unit.

4. The boiler tube leakage 32-channel signal acquisition and I / O control board according to claim 3, characterized in that: The SCSI connector (4) is a 68-pin connector.

5. The boiler tube leakage 32-channel signal acquisition and I / O control board according to claim 4, characterized in that: The relay module (6) has 8 relays.

6. The boiler tube leakage 32-channel signal acquisition and I / O control board according to claim 5, characterized in that: The relay module (6) uses a 12V relay.

7. The boiler tube leakage 32-channel signal acquisition and I / O control board according to claim 4, characterized in that: The optocoupler module (7) has 8 units.

8. The boiler tube leakage 32-channel signal acquisition and I / O control board according to claim 7, characterized in that: The optocoupler module (7) adopts an optocoupler.

9. The boiler tube leakage 32-channel signal acquisition and I / O control board according to claim 1, characterized in that: The control card slot (8) uses a DB37 interface.

10. The boiler tube leakage 32-channel signal acquisition and I / O control board according to claim 1, characterized in that: The communication card slot (5) uses a DB37 interface.

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