CN203759861U - Zigbee-based short circuit switch remote monitoring system for copper electrolysis - Google Patents

Abstract

The utility model provides a zigbee-based remote monitoring system for a short-circuit switch for copper electrolysis, which comprises a monitoring module, a coordinator node module and a routing node module connected in sequence, and the routing node module is respectively connected to a plurality of terminal node modules. The control system is established based on zigbee wireless sensor network technology, which can display the current switch node temperature in real time and accurately locate switch faults, and perform sound and light alarms to display faults, thereby achieving remote wireless monitoring of copper electrolytic DC short-circuit switches. Remote control provides convenience for operators to quickly troubleshoot, greatly improves the work efficiency of managers, optimizes production management, improves the informatization and automation of safe production in the entire copper electrolysis industry, and successfully solves the current market price of such systems Expensive problem, in the domestic copper electrolysis process has very considerable application prospects.

Description

Zigbee-based remote monitoring system for short-circuit switch for copper electrolysis

technical field

The utility model belongs to the technical field of industrial control, relates to a monitoring system used in a copper electrolysis process, in particular to a zigbee-based remote monitoring system for a short-circuit switch for copper electrolysis.

Background technique

The copper electrolysis DC short-circuit switch in the copper electrolysis process itself does not have a device for qualitative and quantitative monitoring of the pneumatic protection circuit. The vacuum reduction fault is an invisible fault, and when the short-circuit switch is repaired in the high-temperature and high-corrosion environment of the copper electrolysis plant The personal safety of maintenance personnel also poses a great threat. my country's electrolytic copper industry has developed extremely fast and is widely used. However, the real-time monitoring system for DC vacuum short-circuit switches is not perfect enough, and even the monitoring equipment has not been widely used. As a result, the pneumatic protection circuit in the copper electrolysis system fails frequently, the production efficiency is low, and the automation level of production and management is not high enough. In recent years, industrial automation has increasingly strong demand for wireless data communication. There have also been some monitoring equipment, such as completing the monitoring system with industrial control machines. However, its cost is high, and its degree of intelligence is not high, which is not conducive to mass use. There are also some wireless communication monitoring devices used, but in practical applications, their anti-interference ability is poor, the signal is unstable, the cost of use (network cost) is high, and the power supply is complicated.

Contents of the invention

The purpose of this utility model is to provide a low-cost remote monitoring system for short-circuit switches for copper electrolysis based on zigbee, which can remotely and wirelessly control the opening and closing of copper electrolysis DC short-circuit switches, display the current temperature status of switch nodes in real time and monitor switch failures. Accurate positioning.

In order to achieve the above object, the technical solution adopted by the utility model is: a kind of short-circuit switch remote monitoring system for copper electrolysis based on zigbee, including a monitoring module, a coordinator node module and a routing node module connected in sequence, and the routing node module is connected with the Multiple terminal node modules are connected.

The control system of the utility model is established based on zigbee wireless sensor network technology, and is composed of three levels of terminal nodes, routing nodes and coordinator nodes. It can display the current switch node temperature status in real time and accurately locate switch faults, and perform sound and light alarms. Display the fault, and then achieve the remote wireless remote control of the copper electrolytic DC short-circuit switch, and record the opening and closing time and times of the switch, and then display the printing results. It provides convenience for operators to quickly troubleshoot, greatly improves the work efficiency of managers, optimizes production management, improves the informatization and automation of safe production in the entire copper electrolysis industry, and successfully solves the problem of expensive systems in the current market. It has a very considerable application prospect in the domestic copper electrolysis process.

Description of drawings

Fig. 1 is a schematic diagram of the system structure of the control system of the present invention.

Fig. 2 is a schematic structural diagram of a terminal node in the control system of the present invention.

Fig. 3 is a schematic structural diagram of routing nodes in the control system of the present invention.

Fig. 4 is a schematic structural diagram of a coordinator node in the control system of the present invention.

Fig. 5 is a control flow chart of the upper computer monitoring module in the control system of the present invention.

In the figure: 1. Terminal node module, 2. Routing node module, 3. Coordinator node module, 4. Monitoring module, 5. Sensor module, 6. Terminal node CC2530 core module, 7. Alarm module, 8. Terminal node LCD Display module, 9. Terminal node RF wireless transceiver module, 10. Terminal node power module, 11. Routing node power module, 12. Routing node CC2530 core module, 13. Routing node RF wireless transceiver module, 14. Coordinator power module, 15. Coordinator node CC2530 core module, 16. Coordinator LCD display module, 17. Serial port transceiver module, 18. Coordinator node RF wireless transceiver module.

Detailed ways

The utility model will be described in detail below in conjunction with the accompanying drawings and specific embodiments.

The control system of the utility model is realized based on the wireless sensor network technology of the zigbee technology. The networking form of the system is a star network, which is composed of terminal nodes, routing nodes and coordinator nodes. The nodes at all levels and the protocol stack formulated by the Zigbee Alliance together constitute the Zigbee wireless sensor network. Zigbee is a technology stipulated in the IEEE 802.15.4 protocol. It is a cheap, low-power, short-distance wireless networking communication technology with strong anti-interference ability. Zigbee works at 2.4GHz, and its purpose is mainly to solve device interconnection. It is mainly a wireless network solution for sensors, with low requirements for bandwidth and power consumption. Zigbee's low data rate guarantees lower power consumption. Therefore, battery power can be used, and Zigbee devices can "sleep" most of the time, only activated when working or periodically updated, so that the battery life can reach several years. Zigbee network also has self-forming and self-healing capabilities.

In Zigbee network:

The terminal node has no specific responsibility for maintaining the network structure. It can sleep or wake up, so it can be a battery-powered device that can work for 6 to 24 months with only an ordinary AA battery. The storage space of the terminal device is relatively small. It is mainly composed of an industrial control box that controls the monitoring nodes of each switch. The industrial control box mainly includes CC2530 module, LCD display module, alarm module, wireless transceiver module, relay and other equipment. Each module will collect and transmit the switching value and temperature value, and send the multi-channel signal collected by the terminal node (endpoint) to the routing node (router) of the zigbee network after processing, and then the routing node will pass through the zigbee wireless network It is transmitted to the coordinator node (coordinator), and then the coordinator node transmits the information to the computer equipment at the monitoring end through RS232. The industrial control box has a switch closing button, an opening button, a fault indicator light, an LCD display, a transfer switch, and a fault reset button.

The function of the routing node is mainly to allow other devices to join the network, multi-hop routing and to assist its own battery-powered end-devices in communication. It mainly includes microcontroller module, wireless communication module, and power management module.

The coordinator node is responsible for starting the entire network. It is also the first device of the network. The coordinator selects a channel and a network ID, and then starts the entire network. The coordinator can also be used to assist in establishing security layer and application layer bindings in the network (bindings). The role of the coordinator mainly involves the startup and configuration of the network. Once this is done, the coordinator works like a router. Due to the distributed nature of the ZigBee network itself, the subsequent operation of the entire network no longer depends on the existence of the coordinator. It is mainly composed of a wireless communication module, a microcontroller function module, a serial communication module, and a power supply function module.

The monitoring module communicates with the coordinator module through RS232, and receives the status information of temperature and switch value transmitted from the terminal node, and displays the status information, alarms the abnormal status beyond the safe temperature range, and at the same time, the PC-side user management system sends out The control information is processed and forwarded to the coordinator node of the Zigbee network. The address in the coordinator node forwards the control information to the corresponding routing node, and then the routing node forwards the control information to the terminal node to monitor and control the operation of the short-circuit switch, and at the same time generate a temperature Reports for logging and alarm logging.

As shown in FIG. 1 , the control system of the present invention includes a monitoring module 4 , a coordinator node module 3 and a routing node module 2 connected in sequence, and the routing node module 2 is connected to a plurality of terminal node modules 1 respectively.

As shown in Figure 2, the terminal node module 1 in the control system of the present invention includes a sensor module 5, a terminal node CC2530 core module 6, a terminal node RF wireless transceiver module 9 and a terminal node power supply module 10 connected in sequence, and the terminal node CC2530 core module 6 is also connected with alarm module 7 and terminal node LCD display module 8 respectively.

The sensor module 5 adopts DS18B20 digital temperature sensor, and the internal structure of the digital temperature sensor is mainly composed of five parts: temperature sensor, A/D converter, signal processor, memory and interface circuit. Its main features are accurate temperature measurement with a temperature resolution of 0.5°C; wide measurement range from -55°C to +125°C; DS18B20 digital temperature sensor is easy to wire and can be used in various occasions after being packaged. Such as pipeline type, screw type, magnet adsorption type, stainless steel package type, and various models. It can fully meet the high temperature and high corrosion environmental requirements of copper electrolysis plants.

The alarm module 7 is mainly composed of a buzzer and an LED alarm light. The red light indicates that the short-circuit switch fails, the yellow light indicates that the system is abnormal, and the green light indicates that the short-circuit switch operates normally; when the short-circuit switch fails and the system operates abnormally, the buzzer An alarm sound will be issued accordingly, prompting the maintenance personnel to check the equipment and system. The LCD display module adopts a 128×64 dot matrix liquid crystal module with a Chinese character library. This liquid crystal module has multiple interface modes of 4-bit or 8-bit parallel, 2-wire or 3-wire serial, and its display resolution is 128×64, built-in 8192 (16×16 dot matrix) Chinese characters and 128 16×8 dot ASCII character sets. It can display Chinese characters in 8×4 rows and 16×16 dot matrix, and can also complete graphic display; low voltage and low power consumption are another notable feature. The 12864 liquid crystal module displays the real-time temperature information processed by the processor on its screen, and the maintenance personnel can intuitively observe the real-time temperature change of the short-circuit switch and take corresponding measures.

As shown in FIG. 3 , the routing node module 2 in the control system of the present invention includes a routing node power supply module 11 , a routing node CC2530 core module 12 and a routing node RF wireless transceiver module 13 connected in sequence.

As shown in Figure 4, the coordinator node module 3 in the control system of the present invention comprises the coordinator node power supply module 14, the coordinator node CC2530 core module 15 and the coordinator RF wireless transceiver module 18 connected successively, and the coordinator node The CC2530 core module is also connected with the coordinator LCD display module 16 and the serial transceiver module 17 respectively.

The serial port module 17 is a PL2303 interface chip of Polific Company, which can provide a solution for convenient connection of an RS232 full-duplex asynchronous serial communication device and a USB functional interface. It has the characteristics of strong compatibility, high information throughput rate, stable performance, and strong anti-interference ability. The working principle of the coordinator node module 3 is to process the real-time information sent by each routing node through the coordinator node through the core module 15 of the coordinator CC2530, store it in the chip storage unit, and transmit the real-time information to the monitoring module 4 through RS232. Similarly, the control information of the monitoring module 4 is also transmitted to the coordinator CC2530 core module 15 through RS232, and is transmitted to the routing node module 2 through the coordinator RF wireless transceiver module 18, and then the routing node module 2 passes the routing node RF wireless transceiver module 13 Passed to the interrupt node to control the corresponding short circuit switch.

All core modules and all wireless transceiver modules in the control system of the utility model are realized based on the CC2530 wireless radio frequency chip. CC2530 wireless radio frequency chip is a 2.4GHz radio frequency system single chip fully compliant with ZigBee technology, suitable for various wireless network nodes. Its main features are small size, high performance and low power consumption, excellent wireless receiving sensitivity and strong anti-interference, programmable output power up to 4.5dbm, and only need a few external components. The CC2530 radio frequency chip embeds a high-performance and low-power 8051 microcontroller core, integrates a 14-bit analog-to-digital conversion ADC module, has battery monitoring and temperature sensing functions, and has rich interface resources such as serial ports. It also integrates a RF radio transceiver module in the 2.4GHz frequency band that conforms to the IEEE802.15.4 standard.

IEEE 802.15.4 is a low-speed wireless personal area network standard. The standard defines a physical layer (PHY) and a medium access control layer (MAC). This low-rate wireless personal area network has a simple network structure, low cost, limited power and flexible throughput. The main goals of low-rate wireless personal area networks are to achieve easy installation, reliable data transmission, short-range communication, extremely low cost, reasonable battery life, and have a simple and flexible communication network protocol.

The host computer software of the monitoring module 4 is written in Object Pascal language. Delphi is a visual software development tool developed by the famous Borland (now merged with Inprise). Delphi is known as the fourth-generation programming language, which has the characteristics of simplicity, high efficiency and powerful functions. At the same time, delphi is based on form and object-oriented methods, high-speed compiler, powerful database support, closely integrated with Windows programming, powerful and mature component technology. The program is mainly divided into an automatic part and a manual part. The manual part is switched through the control button of the control box of the terminal node, and each node is manually controlled separately. When the program enters the automatic part, the upper computer must first establish communication with the node control box, then determine the data input, and then judge whether there is an input signal and whether the input signal is valid. If it is invalid, return to the fault processing interface for processing; if the signal is valid, enter the corresponding interface. The interface performs signal processing, and after the above is completed, the program ends. Its control flow chart is shown in Fig. 5. The monitoring module 4 mainly includes the initial login interface, the status display interface of each copper electrolytic short circuit switch of the terminal node, the remote control interface, the alarm record and historical data query interface, the user setting and management interface, etc. The short-circuit switch control interface mainly controls the opening and closing of the short-circuit switch, displays its opening and closing status, and accumulates the number of switch openings during manual operation and remote automatic control of each short-circuit switch. The copper electrolytic short-circuit switch status display interface mainly displays the real-time temperature change curve of the short-circuit switch node, and various fault states of the short-circuit switch, among which red indicates failure, yellow indicates abnormal system operation, and green indicates normal operation. The short-circuit switch data recording interface is mainly used to record the collected historical temperature data and alarm times, display network information at the same time, and save relevant data. The system setting interface is mainly used to set each port, speed, drawing speed, data recording interval, etc.

The control system of the utility model is a remote wireless monitoring system based on zigbee technology developed and designed for a DC short-circuit switch in a copper electrolysis process. The terminal node module 1 passes the real-time information of the short-circuit switch collected by the temperature sensor through the core module 6 of the terminal node CC2530, and stores the collected data into the memory of the module through A/D conversion, and the real-time information data passes through the terminal node RF wireless The transceiver module 9 transmits to the routing node module 2, and the routing node module 2 transmits the real-time information data to the coordinator node module 3 through the routing node RF wireless transceiver module 13. The coordinator node module 3 processes the real-time information collected by each terminal node module 1 through the core module 15 of the coordinator CC2530, stores it in the chip storage unit, and transmits the real-time information to the monitoring module 4 through RS232. Similarly, the control information of the monitoring module 4 is also transmitted to the core module 15 of the coordinator CC2530 through RS232, and transmitted to the next-level routing node module 2 through the wireless transceiver module, and then transmitted to the terminal node module 1, thereby controlling the corresponding short circuit switch. The short-circuit switch monitoring system follows the design and manufacture principles of safety, reliability, accuracy, real-time and ease of maintenance, and has great practical value and promotion value in practical applications.

Claims (5)

1. the short circuiting switch long distance control system of the cupric electrolysis based on zigbee, it is characterized in that, comprise the monitoring module (4), coordinator node module (3) and the routing node module (2) that are connected successively, routing node module (2) is connected with multiple terminal node modules (1) respectively.

2. the short circuiting switch long distance control system of the cupric electrolysis based on zigbee according to claim 1, it is characterized in that, described terminal node module (1) comprises the sensor assembly (5), terminal node CC2530 nucleus module (6), terminal node RF radio receiving transmitting module (9) and the terminal node power module (10) that are connected successively, and terminal node CC2530 nucleus module (6) is also connected with terminal node LED display module (8) with alarm module (7) respectively; Sensor assembly (5) adopts DS18B20 digital temperature sensor.

3. the short circuiting switch long distance control system of the cupric electrolysis based on zigbee according to claim 1, it is characterized in that, described routing node module (2) comprises the routing node power module (11), routing node CC2530 nucleus module (12) and the routing node RF radio receiving transmitting module (13) that are connected successively.

4. the short circuiting switch long distance control system of the cupric electrolysis based on zigbee according to claim 1, it is characterized in that, described coordinator node module (3) comprises the coordinator node power module (14), coordinator node CC2530 nucleus module (15) and the telegon RF radio receiving transmitting module (18) that are connected successively, and coordinator node CC2530 nucleus module is also connected with serial ports transceiver module (17) with telegon LCD display module (16) respectively.

5. the short circuiting switch long distance control system of the cupric electrolysis based on zigbee according to claim 4, is characterized in that, described serial ports transceiver module (17) adopts PL2303 interface chip.