CN209818268U - PCS pump control system - Google Patents
PCS pump control system Download PDFInfo
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- CN209818268U CN209818268U CN201920158205.0U CN201920158205U CN209818268U CN 209818268 U CN209818268 U CN 209818268U CN 201920158205 U CN201920158205 U CN 201920158205U CN 209818268 U CN209818268 U CN 209818268U
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Abstract
The utility model provides a PCS pump control system, a serial communication port, include: a control unit for providing a control signal; the sensor unit is connected with the control unit and controls the sensor unit to detect the liquid level according to the control signal; the water pump set comprises at least one water pump, is connected with the control unit and works according to the control signal of the control unit; and the power supply unit is used for supplying power to the pump control system. The utility model discloses a modularization, intelligent design are through installing this system in each pump station or sewage treatment station to adopt digital communication networking technology to unite communication, realize the centralized control of a plurality of water pumps, make its working process obtain accurate reliable control, this pump control system still has advantages such as small, with low costs, maintain few, unmanned on duty and simple to operate.
Description
Technical Field
The invention relates to the technical field of water treatment, in particular to a PCS pump control system applied to the technical field of water treatment.
Background
For sewage treatment enterprises, a pump control system is the most core part, and water pumps, medicine pumps or sludge pumps at all levels can be accurately and reliably controlled through a set of complete pump control system. The traditional pump control system mostly adopts a relay or a PLC control system, but most of the control systems have larger volume, higher cost and longer construction period and maintenance period, and particularly, the applicability of the two pump control systems is more limited for the treatment of small and medium-sized domestic sewage in villages and towns or remote urban areas. Along with the development of science and technology, the intellectualization and centralization of the sewage treatment industry will be the future development direction, so a pump control system which is small in size, low in cost and convenient to install needs to be designed, and the development requirements of the future sewage treatment industry are met.
Disclosure of Invention
In view of the above, the main object of the present invention is to provide a PCS pump control system, which is designed in a modularized and intelligent manner, and is installed in each pump station or sewage treatment station, and is communicated in a digital communication networking technology, so as to realize centralized control of a plurality of water pumps, and to accurately and reliably control the working process of the pumps.
The invention adopts the technical scheme that a PCS pump control system comprises:
a control unit for providing a control signal;
the sensor unit is connected with the control unit and controls the sensor unit to detect the liquid level according to the control signal;
the water pump set comprises at least one water pump, is connected with the control unit and works according to the control signal of the control unit;
and the power supply unit is used for supplying power to the pump control system.
Therefore, the pump control system is installed on each pump station or sewage treatment station, the industrial personal computer performs unified control operation, centralized control on sewage treatment tasks of a plurality of pump stations is realized, and the pump control system has the advantages of low cost, less maintenance, remote monitoring, unattended operation and the like, is wide in application range, and is a technology worthy of popularization in the intelligent development of the future sewage treatment industry.
Wherein the control unit includes:
the system comprises a microcontroller, and a relay control module, a sensor control module and a communication module which are respectively connected with the microcontroller;
the relay control module is connected with the water pump set, the sensor control module is connected with the sensor unit, and the communication module is used for connecting other control units or equipment.
After the microcontroller receives the control instruction, the relay is controlled to be switched on through the relay control module, so that the water pump set starts to work, the sensor unit is controlled to carry out water level detection through the sensor control module, and the communication unit can be communicated with other control units or equipment.
Optionally, the microcontroller includes an STC15W4K series single chip microcomputer.
Therefore, the series of single-chip microcomputers are low in price, can control six water pumps at most, and have high cost performance.
Optionally, the communication module includes an RS485 interface.
By last, this system can support a plurality of control unit serial communication through Modbus communication protocol, and its hardware only needs RS485 interface and two signal lines can gather all signals to communicate through RS485 interface and any third party's equipment, have advantages such as the cloth net is convenient, simple structure, safe and reliable, and interference killing feature is extremely strong, increase of service life greatly.
Wherein, the sensor unit includes two at least angle float switches, and this angle float switch includes:
the casing, the airtight inside hollow structure that forms of casing, inside hollow structure cut apart into upper and lower two parts by an inverted cone structure, are equipped with in this inverted cone structure and trigger the steel ball, and inverted cone structure top is equipped with the stainless steel separation blade, and this stainless steel separation blade passes through a communication wire and connects the control unit.
In the prior art, the traditional liquid level measurement mode is usually a pressure sensor and a float switch, wherein the hydrostatic measurement method mostly adopts a mode of measuring hydrostatic pressure by the pressure sensor to obtain a liquid level value, and the mode needs a pressure probe to contact sewage, and often causes inaccurate measurement due to the blockage of the front end probe by the sewage; the float switch adopts a float to drive the microswitch to send out a switch signal, the mode requires a certain volume to place a steel ball and the microswitch, and the signal is completed by the mechanical action of the microswitch. The problems are that the volume is large and the reliability of mechanical action is poor. Based on the characteristics and the defects, the angle floating ball switch designed by the invention is divided into an upper part and a lower part which are separated by an inverted cone structure, the lower part is a sealed cavity, the inverted cone structure is internally provided with a triggering steel ball, a stainless steel baffle is arranged above the inverted cone structure, the two ends of the inverted cone are respectively provided with a positive pole and a negative pole, the angle floating ball switch is vertical to the water surface, when the water level rises to exceed the sealed cavity, the angle floating ball switch inclines due to the buoyancy effect, when the inclination reaches a certain angle, the triggering steel ball leaves the bottom of the cone and contacts with the stainless steel baffle above, so that the cone structure is communicated with the stainless steel baffle to trigger a switch signal, and besides, because the liquid level sensor cannot detect whether the liquid level is damaged or not, the liquid level measurement can be carried out by arranging two or more angle floating ball switches, and simultaneously sending the measured water level signal to the control, when a plurality of water level signals are consistent, the operation of the plurality of angle float switches is normal, when the plurality of water level signals are inconsistent, the damage of one of the angle float switches is indicated, and at the moment, the control unit can send a fault signal to a remote industrial personal computer or a controller to inform maintenance personnel of timely replacement so as to ensure the normal operation of the pump control system.
The angle float switch shell is characterized in that the outer shell of the angle float switch shell is made of stainless steel, and the inner shell is provided with an insulating layer.
By last, because this angle float switch places in aqueous for a long time, consequently its shell adopts stainless steel, can prevent to corrode, and the inner shell is equipped with the insulating layer, prevents that water infiltration from getting into to destroy inner structure.
Optionally, the power supply unit includes a motor starter of the MS116 type that switches the water pump set on and off through a contactor of the A16-30-10 type.
From above, this power supply unit drives the water pump through motor starter to realize functions such as short-circuit protection, undervoltage protection, open-phase protection, overload protection and isolation of water pump package through contactor switch.
In a further improvement, the control unit, the sensor unit and the power supply unit are connected through a flame-retardant waterproof connector clip.
By last, this connector adopts and connects the structure of inserting fast, under the circumstances of guaranteeing contact area and pressure, adopts fire-retardant waterproof connector, can guarantee to connect firm nature and the reliability of connecing.
The improved water heater is further improved by comprising a box body, wherein the control unit, the sensor unit, the water pump set and the power supply unit are contained in the box body, and an aeration pipe is also arranged in the box body and used for generating heat to prevent the temperature of the box body from being too low; and/or
The convection double fans enable air to be convected to prevent the temperature of the box body from being overhigh.
From the above, considering that the temperature difference between north and south of China is large, the highest temperature point of some areas is higher than the temperature of the electronic element. Therefore, the PCS pump control system adopts a temperature control design, and the system is ensured to work at a proper temperature. The temperature control design scheme is as follows: the air convection is realized by adopting a convection double-fan design in the box body for the high-temperature environment in south China, and meanwhile, the sun shield is additionally arranged to reduce infrared radiation; for the low-temperature environment in winter in the north, the module and the aerator pipe are arranged in one box body, and the heat generated by the aerator pipe and the heat generated by the module body are enough to ensure the normal work of the module.
Drawings
FIG. 1 is a block schematic diagram of a PCS pump control system of the present invention;
FIG. 2 is a block schematic diagram of the control unit of the present invention;
FIG. 3 is a schematic view of the angle float switch of the present invention.
Detailed Description
The PCS (Pump Control System) pump Control system provided by the invention adopts modular connection, a miniaturized design and a digital communication networking technology, and has the biggest bright spot of small volume, quick connection and maintenance-free property. The construction period and the debugging period can be greatly shortened, the maintenance cost is reduced, the cost of an enterprise is reduced, and the money is returned quickly. Compared with the existing universal relay or PLC control system, the PCS pump control system has the characteristics of small volume, low cost, less maintenance, remote monitoring, unattended operation, convenient net distribution expansion, low energy consumption, short construction period and the like. Is a technology worth popularizing in the intelligent development of the sewage treatment industry in the future.
The operation of the present invention will now be described in detail with reference to the accompanying drawings.
As shown in fig. 1, the PCS pump control system provided by the present invention includes:
the industrial personal computer 100 is used for man-machine interaction and can realize remote centralized monitoring or control;
a control unit 200, including a plurality of control units, each of which is pre-installed with a pump control software system and then respectively installed in each pump station or sewage treatment station, the plurality of control units communicate with each other, the pump control unit 200 can independently operate by means of pump control software, can also receive instructions of the industrial personal computer 100, and is centrally controlled by the industrial personal computer 100;
a water pump set 300 connected to the control units 200 and operated according to control signals thereof, wherein each control unit 200 can support the control of at most six water pumps;
a sensor unit 400 connected to the control unit 200, for controlling the sensor unit to perform liquid level detection according to a control signal thereof;
the power supply unit 500 provides a 330V power supply for the water pump, a motor starter of an MS116 model is arranged in the power supply unit, the motor starter provides power for the water pump group through a contactor switch of an A16-30-10 model and the water pump group 300, and the functions of short circuit protection, undervoltage protection, open-phase protection, overload protection, isolation and the like of the water pump group are realized.
As shown in fig. 2, the hardware part of the control unit 200 includes a microcontroller 201, and a relay control module 202, a sensor control module 203, a communication module 204 and a power supply module 205 respectively connected thereto; the software part of the control unit 200 adopts C language to compile software program, and downloads the software program to the chip through the USB interface, and the program is convenient to encrypt, and can be even remotely transmitted to the user, the software can not be opened in the middle of the client, and the client can directly download the software program to the chip through the USB cable after downloading the software program to the computer, thereby being extremely convenient and fast;
the microcontroller 201 can select an STC15W4K series single chip microcomputer, the price of the series single chip microcomputer is low, a maximum of six water pumps can be controlled, and the cost performance is high;
the relay control module 202 comprises a plurality of groups of relays, the voltage of a relay coil is 5V, the driving current is 5mA, the contact capacity is 250VAC and 10A, and high/low level triggering can be selected;
the sensor control module 203 is connected to the sensor unit 400, transmits a control command to the sensor unit 400, and receives a trigger signal returned therefrom;
the communication module 204 is constructed by adopting an RS485 interface, a large number of signal lines are not needed, each pump station can acquire all signals by only 2 signal lines, Modbus RTU or serial port communication can be performed through an RS485 hardware interface and other control units or third-party equipment, and simultaneously signals are uploaded to different places through a 4G communication module, so that a remote access control function can be realized;
the power supply module adopts a universal 220V-to-5V, 1A power supply and is used for providing working voltage for the relay, the singlechip and the sensor control module 203.
The sensor unit 400 uses a liquid level switch as a sensor to measure the liquid level, and the traditional liquid level measurement method usually adopts a pressure sensor and a float switch, wherein the hydrostatic measurement method mostly adopts a method of measuring hydrostatic pressure by the pressure sensor to obtain a liquid level value, and the method needs a pressure probe to contact sewage, and often causes inaccurate measurement due to the blockage of the front end probe by dirt; the float switch adopts a float to drive the microswitch to send out a switch signal, the mode requires a certain volume to place a steel ball and the microswitch, and the signal is completed by the mechanical action of the microswitch. The problems are that the volume is large and the reliability of mechanical action is poor. Based on the characteristics and the defects, the invention designs the angle floating ball switch;
as shown in fig. 3, the whole of the angle float switch is similar to a cylinder, the shell is made of stainless steel, and the density of the stainless steel is greater than that of water according to the buoyancy principle, so that the interior of the angle float switch needs to be enlarged in drainage volume by adopting the hollow principle, and the angle float switch is suspended at the water level to be measured;
an insulating layer 401 is arranged inside a housing of the angle float switch to ensure that an internal structure is insulated from an external stainless steel housing, an internal hollow structure of the angle float switch is divided into an upper part and a lower part, the two parts are separated from each other, the lower part is a sealed cavity 402, the upper part is provided with a V-shaped cone structure 403, the cone structure 403 is made of stainless steel, two ends of the cone structure are respectively a positive electrode and a negative electrode, a cone wall forms an angle with the inner wall of the angle float switch, the angle is generally set to be 45 degrees, a trigger steel ball is arranged in the cone structure, a stainless steel blocking piece 404 is arranged on the upper part of the cone structure, and the stainless steel blocking piece 404 is connected with the. Under the standard condition, the trigger angle of the angle float switch is 45 degrees, when the water level rises, the angle float switch inclines, after reaching the trigger angle, the trigger steel ball contacts with the stainless steel baffle plate to enable the cone to be connected with the stainless steel baffle plate, a switch signal is generated and transmitted to the control unit 200, at the moment, the control unit 200 can control the water pump needing liquid level control to be started and stopped to execute a drainage command according to the switch signal, when the water level falls and the inclination angle of the angle float switch is smaller than the trigger angle, the connection signal is disconnected, and at the moment, the water pump stops working;
if the liquid level sensor on the market is damaged, automatic alarm cannot be given, so that the water pump is often damaged or the well is burst, and if the fault needs to be found, people need to regularly patrol. The sensor unit of the system is used by installing two angle floating ball switches in a shell, because the angle floating ball switches are manufactured by the same mould and process, the signals output by the two switches are the same at the limit water level, and the probability of the two switches being damaged simultaneously is far lower than that of one switch, therefore, when one switch is damaged due to the reasons of service life and the like, the signals output by the two switches at the limit water level are different inevitably, whether the two signals are the same or not can be judged in a single chip microcomputer of the pump control system, if the two signals are different, the single chip microcomputer can output a fault signal to be sent to a remote end to inform a maintainer of replacing the sensor, and meanwhile, a field fault lamp can be lightened, so that the sensor can be informed to the operation and the maintainer of the fault in advance; meanwhile, as the angle float switch is normal, the normal operation of the system can be ensured, and the scheme well solves the accident caused by the fault of the current liquid level sensor;
the PCS pump control system adopts a digital communication technology for collecting analog quantity signals such as liquid level, flow, water quality monitoring and the like, and has obvious advantages in the aspects of communication distance, interference resistance, expansion and the like;
in addition, the PCS pump control system is subjected to a plurality of optimization designs on hardware structures and materials according to construction environments and working environments;
1. vibration:
the PCS pump control system is provided with a plurality of vibration sources such as a running motor, supports of various devices, natural wind in open air installation and the like, so that the PCS pump control system is designed to be shock-resistant and can resist the vibration of 0.1mm/S and the vibration of 0.015mm in double amplitude.
2. Corrosion property:
in the sewage treatment industry, the sewage contains corrosive gases such as hydrogen sulfide and methane, so that the service life of electronic products is greatly influenced. Therefore, the PCS pump control system is designed and treated for corrosion resistance, all materials are made of corrosion-resistant materials, all electronic circuit parts are designed for water resistance and gas resistance, and therefore the corrosion resistance of the PCS pump control system is far better than that of the existing universal control system.
3. Temperature:
considering that the temperature difference between north and south of China is large in winter and summer, the highest temperature point of some regions is higher than the temperature of the electronic element. Therefore, the PCS pump control system adopts a temperature control design. Ensuring that the system operates at a proper temperature. The temperature control design scheme is as follows:
for the high-temperature environment in south China, the module adopts a convection double-fan design to realize gas convection, and meanwhile, a sun shield is additionally arranged to reduce infrared radiation; for the low-temperature environment in winter in the north, the module and the aerator pipe are arranged in one box body, and the heat generated by the aerator pipe and the heat generated by the module body are enough to ensure the normal work of the module.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (9)
1. A PCS pumping system, comprising:
a control unit for providing a control signal;
the sensor unit is connected with the control unit and controls the sensor unit to detect the liquid level according to the control signal;
the water pump set comprises at least one water pump, is connected with the control unit and works according to the control signal of the control unit;
and the power supply unit is used for supplying power to the pump control system.
2. The system of claim 1, wherein the control unit comprises:
the system comprises a microcontroller, and a relay control module, a sensor control module and a communication module which are respectively connected with the microcontroller;
the relay control module is connected with the water pump set, the sensor control module is connected with the sensor unit, and the communication module is used for connecting other control units or equipment.
3. The system of claim 2 wherein said microcontroller comprises a single chip microcomputer of the STC15W4K series.
4. The system of claim 3, wherein the communication module comprises an RS485 interface.
5. The system of claim 1, wherein the sensor unit comprises at least two angle float switches, the angle float switches comprising:
the casing, the airtight inside hollow structure that forms of casing, inside hollow structure cut apart into upper and lower two parts by an inverted cone structure, are equipped with in this inverted cone structure and trigger the steel ball, and inverted cone structure top is equipped with the stainless steel separation blade, and this stainless steel separation blade passes through a communication wire and connects the control unit.
6. The system of claim 5, wherein the housing of the angle float switch is made of stainless steel and the inner housing is provided with an insulating layer.
7. The system of claim 1, wherein the power unit includes a MS116 motor starter that switches the water pump set through a model a16-30-10 contactor.
8. The system of claim 1, wherein the control unit, the sensor unit, the power supply unit and the water pump set are connected through a flame-retardant waterproof plug connector.
9. The system of claim 1, further comprising a box housing the control unit and the power supply unit, and an aeration pipe disposed in the box for generating heat to prevent the box from having too low a temperature; and/or
The convection double fans enable air to be convected to prevent the temperature of the box body from being overhigh.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201920141398 | 2019-01-25 | ||
| CN2019201413989 | 2019-01-25 |
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| CN209818268U true CN209818268U (en) | 2019-12-20 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109737043A (en) * | 2019-01-25 | 2019-05-10 | 北京中斯水灵水处理技术有限公司 | A PCS pump control system |
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2019
- 2019-01-29 CN CN201920158205.0U patent/CN209818268U/en active Active
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109737043A (en) * | 2019-01-25 | 2019-05-10 | 北京中斯水灵水处理技术有限公司 | A PCS pump control system |
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