Design and Application of Power Monitoring System of Nexteer Automotive Systems (Suzhou) Co., Ltd.
2023-11-06 22:07:46
Introduce the power monitoring system of Nexteer Automotive Systems (Suzhou) Co., Ltd., using intelligent power meters to collect various electrical parameters and switching signals from the power distribution site. The system adopts the combination of optical networking and local networking. After networking, it is transmitted to the background through the optical fiber network. The real-time monitoring of the power distribution circuit of the substation is realized by the Acrel-2000 power monitoring system.
Yang Junjun
1 Ankerui Electric Co., Ltd., Jiading, Shanghai 201801, China;
Abstract: This paper introduces the power monitoring system of Nexteer Automotive Systems (Suzhou) Co., Ltd., which uses intelligent power meters to collect various electrical parameters and switching signals from the power distribution site. The system adopts the combination of optical networking and local networking. After networking, it is transmitted to the background through the optical fiber network. The real-time monitoring of the power distribution circuit of the substation is realized by the Acrel-2000 power monitoring system.
Keywords: large manufacturing enterprise; Nexteer Automotive Systems (Suzhou) Co., Ltd.; 0.4KV substation; intelligent power meter; Acrel-2000; power monitoring system
0. Overview
Nexteer Automotive Systems (Suzhou) Co., Ltd. is located in the east of Nanzhongxin Avenue, Fengli Street, Xietang Town, Suzhou City. The factory covers an area of ​​4.6 hectares with a total investment of 45 million US dollars.
This project is a power distribution monitoring system for the distribution equipment set up by Nexteer Automotive for the North-South Substation. According to the requirements of power distribution system management, it is necessary to separately monitor the low-voltage distribution of the two substations in the two substations of the two factories in Nexteer, and also need to access the distribution of five large air compressors in the workshop. Loops to ensure safe, reliable and efficient use of electricity.
The Acrel-2000 low-voltage intelligent power distribution system makes full use of the latest developments in modern electronic technology, computer technology, network technology and fieldbus technology, and performs distributed data collection and centralized monitoring and management of the variable power distribution system. The secondary equipment of the power distribution system is networked, and the field devices of the distributed power distribution stations are connected as an organic whole through the computer and the communication network to realize remote monitoring and centralized management of the power grid operation.
1. System structure description
The monitoring system mainly realizes the electricity monitoring and power management of the 0.4kV power distribution system of two substations of Nexteer Automobile. The monitoring range is from the low-voltage incoming cabinets of the 0.4KV substation, 105 sets of the switch cabinets and the feeder cabinets. The guide type electric energy meter of the DTSF1352-CF and the 5 air compressor power distribution circuit in the workshop Corey's self-made DTSF1352-CF rail-type power meter realizes remote real-time monitoring and power management in the background by monitoring the above-mentioned monitoring range. The system has 73 multi-function power meters in the Southern District Substation and 3 multi-function power meters in the air compressor circuit in the South District. It is divided into 5 buses to access the central collection device in the south, and 31 multi-function instruments in the North District Substation. And the North District Air Compressor 2 multi-function meters, divided into 4 buses to access the North Center collection device, and then the fiber network is pulled to the main machine room monitoring host to realize the data connection between the instrument on the bus and the monitoring host.
The monitoring system adopts a hierarchical distributed structure, that is, the station control layer, the communication layer and the interval layer; as shown in Figure (1):
.png)
Figure (1) Low-voltage network topology
The interval device layer is mainly: Ankerui multi-function network power meter, switch quantity, analog quantity acquisition module and intelligent circuit breaker. These devices are respectively installed in the electrical cabinet corresponding to the corresponding primary equipment. These devices all adopt RS485 communication interface, and realize on-site data collection through the on-site MODBUS bus and the optical network networking communication.
The network communication layer is mainly: serial port server and network switch, its main function is to convert RS485 signal into TCP/IP signal, and complete data interaction between field layer and station control layer.
Station control management: equipped with high-performance industrial computers, monitors, UPS power supplies, printers and other equipment. The monitoring system is installed on the computer to collect and display the running status of the field device and display it to the user in the form of human-computer interaction.
The above network instruments adopt RS485 interface and MODBUS-RTU communication protocol, RS485 adopts shielded line transmission, generally adopts two connections, the wiring is simple and convenient; the communication interface is half-duplex communication, that is, both sides of the communication can receive and send data but Only data can be sent or received at the same time, and the maximum data transmission rate is 10Mbps.
The RS485 interface is a combination of balanced driver and differential receiver. It has enhanced noise immunity and allows up to 32 devices to be connected on the bus with a maximum transmission distance of 1.2km.
2. Main functions of power monitoring system
2.1 Data Acquisition and Processing
Data collection is the basis of power distribution monitoring. Data acquisition is mainly completed by the underlying multi-function network instrument, realizing local real-time display of remote data. The signals that need to be collected include: three-phase voltage U, three-phase current I, frequency Hz, power P, power factor COSφ, electrical Epi, and remote device operating status.
The data processing mainly displays the electric parameters collected as required in real time to the user, and achieves the automation and intelligent requirements of the power distribution monitoring, and simultaneously stores the collected data into the database for the user to inquire.
2.2 Human-computer interaction
The system provides a simple, easy to use, and good user interface. Using the full Chinese interface, the CAD graphic shows the electrical main wiring diagram of the low-voltage power distribution system, showing the status of the power distribution system equipment and the corresponding real-time operating parameters, the screen timing wheel patrol switching; the screen real-time dynamic refresh; analog quantity display; switch quantity display; continuous Record display, etc.
2.3 Historical events
The historical event viewing interface is mainly for users to view the fault records, signal records, operation records, and over-limit records that have been made to provide convenient and friendly human-computer interaction. Through the historical event viewing platform, you can easily locate you according to your own requirements and query conditions. The historical events to be viewed provide good software support for you to grasp the operation of the entire system.
2.4 Database Establishment and Query
It mainly completes remote measurement and remote signal timing collection, and establishes a database to generate reports on a regular basis for users to query and print.
2.5 User Rights Management
For different levels of users, set different permission groups to prevent the loss of production and life caused by human error, and achieve safe and reliable operation of the power distribution system. Users can log in, log out, change passwords, add deletes, etc. through user management, which is convenient for users to modify accounts and permissions.
2.6 Operating load curve
The load trend curve function is mainly responsible for timing the incoming line and important loop current and power load parameters, and automatically generating the running load trend curve, which is convenient for the user to know the running load status of the equipment in time. Click the corresponding button or menu item to complete the corresponding function switching; you can view the real-time trend curve or historical trend line; you can perform translation, zoom, range conversion and other operations on the selected curve to help users enter the line trend analysis and fault recall. Analysis of the health of the entire system provides intuitive and convenient software support.
2.7 Remote Report Query
The main function of the report management program is to design the report style according to the needs of the user, and filter the data processed in the system to generate the report data required by the user. The program can also use the timed save, print or summon save and print mode for the report file according to the user's needs. At the same time, the program also provides users with the function of generating report file management. The report has the function of freely setting the query time to realize the energy statistics, data export and report printing of day, month and year.
3. Case analysis
The monitoring area of ​​the power monitoring system of Nexteer Automotive Systems (Suzhou) Co., Ltd. is two substations and large air compressors in the workshop. The monitoring scope of this project is the low-voltage inlet cabinet and the communication cabinet of the 0.4KV low-voltage circuit of the power distribution station. The distribution circuit of the feeder cabinet and the air compressor is used for remote real-time monitoring and power management through distributed networking.
The DTSF1352-CF rail type multi-function meter is used for the incoming and outgoing line loops. It is a network power meter designed for power monitoring needs of power systems, industrial and mining enterprises, public facilities, and intelligent buildings. It can measure all conventional power parameters, such as: Three-phase voltage, current, active power, reactive power, power factor, frequency, active power, reactive power, and the instrument has 1 photoelectric isolation switch input contact. This series of network power meters are mainly used in substation automation, distribution network automation, residential power monitoring, industrial automation, energy management systems and intelligent buildings.
The secondary diagram of low-voltage power distribution is shown in Figure (2). The function has electric power telemetry. It mainly monitors the electrical parameters of the operating equipment, including: three-phase voltage, current, power, power factor, electric energy, frequency and other electrical parameters and the three circuits. Phase current; the remote signal function realizes the display of the running status of the field device, mainly including: the switch's branching and closing operation status and communication fault alarm; when the circuit breaker is displaced, an alarm signal will be sent to remind the user to handle the fault in time.
.png)
Figure (2) Low-voltage power distribution quadratic diagram
The remote signal and telemetry alarm function mainly completes the switch operation status and load line monitoring of the low-voltage outlet circuits. The switch position and load limit alarm pop-up alarm interface indicates the specific alarm position and audible alarm, reminding the on-duty personnel to deal with it in time. With historical query function. See picture (3).
.png)
Figure (3) Real-time remote alarm information map and historical telemetry alarm information query
The parameter meter reading function mainly queries the electric parameters of the low-voltage outlet circuits, and has the functions of data export and report printing. The report queries the electrical parameters of the low-voltage loops of the incoming and outgoing lines, including: three-phase current, active power, and active power. The loop name of the report is associated with the database, which is convenient for the user to modify the loop name. See Figure (4).
.png)
Figure (4) Parameter reading
The power consumption report function can select the time period for query, support the electricity cumulative query for any time period, and have the functions of data export and report printing. Provide accurate and reliable energy reports for duty personnel. The loop name of the report is associated with the database, which is convenient for the user to modify the loop name, and also sets the multi-rate meter reading. As shown in the figure below, the precise power consumption of each power distribution circuit in a certain period of time, the user can directly print the report, and can save to other locations in EXCEL format. See Figure (5) and Figure (6).
.png)
Figure (5) Energy report
.png)
Figure (6) Multi-rate electricity report
The schematic diagram of the system communication structure mainly shows the networking structure of the system. The system adopts a layered distributed structure and monitors the communication status of the interval layer devices. Red indicates normal communication and green indicates communication failure. See Figure (7).
.png)
Figure (7) Schematic diagram of system communication structure
The load trend curve interface can be used to visually check the load operation of the loop. View real-time and historical trend curves, click the corresponding button or menu item on the screen to complete the corresponding function switching; help users to enter the trend analysis and fault recall, with curve printing function. Provides intuitive and convenient software support for analyzing the health of the entire system. See picture (8).
.png)
Figure (8) trend graph
The air compressor curve interface can intuitively view the loop load curves of five air compressors, and compare the curves of five air compressors with curve printing function. Provides intuitive and convenient software support for analyzing the operating conditions of air compressor power consumption. See Figure (9).
.png)
Figure (9) Air compressor curve
In the limit setting interface, the upper and lower limits of the alarm can be customized according to the site requirements, including the current, voltage, power, and power factors. The setting is updated in real time, and the software does not need to be restarted, which is convenient, fast, flexible and reliable, and provides intuitive and convenient software support for subsequent users to manage power supply and distribution conveniently. See Figure (10).
.png)
Figure (10) limit setting diagram
4 Conclusion
With the development of society and the wide application of electric power, the power monitoring system has become an inevitable choice for large-scale multi-substation users such as key projects, landmark buildings/large public facilities throughout the country. The Acrel-2000 power monitoring system introduced in this paper In the application of Nexteer Automotive Systems (Suzhou) Co., Ltd., real-time monitoring and power management of the power supply of the low-voltage distribution circuit of the substation can be realized, which not only can display the power consumption of the circuit, but also has the function of network communication, and can be used with the industry. The network switch, serial server, computer and other components constitute a power monitoring system, which facilitates the remote management of the personnel on duty in the substation, which is conducive to saving the time of meter reading and bringing information into power distribution monitoring. The system realizes the analysis and processing of the collected data, displays the running status of each distribution circuit in the substation in real time, and has pop-up alarm dialog box and voice prompt for the closing and closing of the load, and generates various energy reports, analysis curves, Graphics, etc., facilitate remote meter reading and analysis and research of electrical energy. The system is safe, reliable and stable, and provides a reliable and reliable basis for the users of the substation to solve the problem of electricity consumption, and has achieved good social benefits. [2]
references:
[1]. Ren Zhicheng Zhou Zhong. Principles and Application Guidelines of Power Electrical Measurement Digital Instrumentation [M]. Beijing. China Electric Power Press. 2007. 4
[2]. Zhou Zhongbian. Smart grid customer power monitoring and power management system product selection and solution [M]. Beijing. Mechanical Industry Press. 2011.10
About the Author:
Yang Junjun, female, undergraduate. Position: Now working for Ankerui Electric Co., Ltd.
Contact phone, mobile phone, QQ
Http://news.chinawj.com.cn Editor: (Hardware Business Network Information Center) http://news.chinawj.com.cn
Yang Junjun
1 Ankerui Electric Co., Ltd., Jiading, Shanghai 201801, China;
Abstract: This paper introduces the power monitoring system of Nexteer Automotive Systems (Suzhou) Co., Ltd., which uses intelligent power meters to collect various electrical parameters and switching signals from the power distribution site. The system adopts the combination of optical networking and local networking. After networking, it is transmitted to the background through the optical fiber network. The real-time monitoring of the power distribution circuit of the substation is realized by the Acrel-2000 power monitoring system.
Keywords: large manufacturing enterprise; Nexteer Automotive Systems (Suzhou) Co., Ltd.; 0.4KV substation; intelligent power meter; Acrel-2000; power monitoring system
0. Overview
Nexteer Automotive Systems (Suzhou) Co., Ltd. is located in the east of Nanzhongxin Avenue, Fengli Street, Xietang Town, Suzhou City. The factory covers an area of ​​4.6 hectares with a total investment of 45 million US dollars.
This project is a power distribution monitoring system for the distribution equipment set up by Nexteer Automotive for the North-South Substation. According to the requirements of power distribution system management, it is necessary to separately monitor the low-voltage distribution of the two substations in the two substations of the two factories in Nexteer, and also need to access the distribution of five large air compressors in the workshop. Loops to ensure safe, reliable and efficient use of electricity.
The Acrel-2000 low-voltage intelligent power distribution system makes full use of the latest developments in modern electronic technology, computer technology, network technology and fieldbus technology, and performs distributed data collection and centralized monitoring and management of the variable power distribution system. The secondary equipment of the power distribution system is networked, and the field devices of the distributed power distribution stations are connected as an organic whole through the computer and the communication network to realize remote monitoring and centralized management of the power grid operation.
1. System structure description
The monitoring system mainly realizes the electricity monitoring and power management of the 0.4kV power distribution system of two substations of Nexteer Automobile. The monitoring range is from the low-voltage incoming cabinets of the 0.4KV substation, 105 sets of the switch cabinets and the feeder cabinets. The guide type electric energy meter of the DTSF1352-CF and the 5 air compressor power distribution circuit in the workshop Corey's self-made DTSF1352-CF rail-type power meter realizes remote real-time monitoring and power management in the background by monitoring the above-mentioned monitoring range. The system has 73 multi-function power meters in the Southern District Substation and 3 multi-function power meters in the air compressor circuit in the South District. It is divided into 5 buses to access the central collection device in the south, and 31 multi-function instruments in the North District Substation. And the North District Air Compressor 2 multi-function meters, divided into 4 buses to access the North Center collection device, and then the fiber network is pulled to the main machine room monitoring host to realize the data connection between the instrument on the bus and the monitoring host.
The monitoring system adopts a hierarchical distributed structure, that is, the station control layer, the communication layer and the interval layer; as shown in Figure (1):
Figure (1) Low-voltage network topology
The interval device layer is mainly: Ankerui multi-function network power meter, switch quantity, analog quantity acquisition module and intelligent circuit breaker. These devices are respectively installed in the electrical cabinet corresponding to the corresponding primary equipment. These devices all adopt RS485 communication interface, and realize on-site data collection through the on-site MODBUS bus and the optical network networking communication.
The network communication layer is mainly: serial port server and network switch, its main function is to convert RS485 signal into TCP/IP signal, and complete data interaction between field layer and station control layer.
Station control management: equipped with high-performance industrial computers, monitors, UPS power supplies, printers and other equipment. The monitoring system is installed on the computer to collect and display the running status of the field device and display it to the user in the form of human-computer interaction.
The above network instruments adopt RS485 interface and MODBUS-RTU communication protocol, RS485 adopts shielded line transmission, generally adopts two connections, the wiring is simple and convenient; the communication interface is half-duplex communication, that is, both sides of the communication can receive and send data but Only data can be sent or received at the same time, and the maximum data transmission rate is 10Mbps.
The RS485 interface is a combination of balanced driver and differential receiver. It has enhanced noise immunity and allows up to 32 devices to be connected on the bus with a maximum transmission distance of 1.2km.
2. Main functions of power monitoring system
2.1 Data Acquisition and Processing
Data collection is the basis of power distribution monitoring. Data acquisition is mainly completed by the underlying multi-function network instrument, realizing local real-time display of remote data. The signals that need to be collected include: three-phase voltage U, three-phase current I, frequency Hz, power P, power factor COSφ, electrical Epi, and remote device operating status.
The data processing mainly displays the electric parameters collected as required in real time to the user, and achieves the automation and intelligent requirements of the power distribution monitoring, and simultaneously stores the collected data into the database for the user to inquire.
2.2 Human-computer interaction
The system provides a simple, easy to use, and good user interface. Using the full Chinese interface, the CAD graphic shows the electrical main wiring diagram of the low-voltage power distribution system, showing the status of the power distribution system equipment and the corresponding real-time operating parameters, the screen timing wheel patrol switching; the screen real-time dynamic refresh; analog quantity display; switch quantity display; continuous Record display, etc.
2.3 Historical events
The historical event viewing interface is mainly for users to view the fault records, signal records, operation records, and over-limit records that have been made to provide convenient and friendly human-computer interaction. Through the historical event viewing platform, you can easily locate you according to your own requirements and query conditions. The historical events to be viewed provide good software support for you to grasp the operation of the entire system.
2.4 Database Establishment and Query
It mainly completes remote measurement and remote signal timing collection, and establishes a database to generate reports on a regular basis for users to query and print.
2.5 User Rights Management
For different levels of users, set different permission groups to prevent the loss of production and life caused by human error, and achieve safe and reliable operation of the power distribution system. Users can log in, log out, change passwords, add deletes, etc. through user management, which is convenient for users to modify accounts and permissions.
2.6 Operating load curve
The load trend curve function is mainly responsible for timing the incoming line and important loop current and power load parameters, and automatically generating the running load trend curve, which is convenient for the user to know the running load status of the equipment in time. Click the corresponding button or menu item to complete the corresponding function switching; you can view the real-time trend curve or historical trend line; you can perform translation, zoom, range conversion and other operations on the selected curve to help users enter the line trend analysis and fault recall. Analysis of the health of the entire system provides intuitive and convenient software support.
2.7 Remote Report Query
The main function of the report management program is to design the report style according to the needs of the user, and filter the data processed in the system to generate the report data required by the user. The program can also use the timed save, print or summon save and print mode for the report file according to the user's needs. At the same time, the program also provides users with the function of generating report file management. The report has the function of freely setting the query time to realize the energy statistics, data export and report printing of day, month and year.
3. Case analysis
The monitoring area of ​​the power monitoring system of Nexteer Automotive Systems (Suzhou) Co., Ltd. is two substations and large air compressors in the workshop. The monitoring scope of this project is the low-voltage inlet cabinet and the communication cabinet of the 0.4KV low-voltage circuit of the power distribution station. The distribution circuit of the feeder cabinet and the air compressor is used for remote real-time monitoring and power management through distributed networking.
The DTSF1352-CF rail type multi-function meter is used for the incoming and outgoing line loops. It is a network power meter designed for power monitoring needs of power systems, industrial and mining enterprises, public facilities, and intelligent buildings. It can measure all conventional power parameters, such as: Three-phase voltage, current, active power, reactive power, power factor, frequency, active power, reactive power, and the instrument has 1 photoelectric isolation switch input contact. This series of network power meters are mainly used in substation automation, distribution network automation, residential power monitoring, industrial automation, energy management systems and intelligent buildings.
The secondary diagram of low-voltage power distribution is shown in Figure (2). The function has electric power telemetry. It mainly monitors the electrical parameters of the operating equipment, including: three-phase voltage, current, power, power factor, electric energy, frequency and other electrical parameters and the three circuits. Phase current; the remote signal function realizes the display of the running status of the field device, mainly including: the switch's branching and closing operation status and communication fault alarm; when the circuit breaker is displaced, an alarm signal will be sent to remind the user to handle the fault in time.
Figure (2) Low-voltage power distribution quadratic diagram
The remote signal and telemetry alarm function mainly completes the switch operation status and load line monitoring of the low-voltage outlet circuits. The switch position and load limit alarm pop-up alarm interface indicates the specific alarm position and audible alarm, reminding the on-duty personnel to deal with it in time. With historical query function. See picture (3).
Figure (3) Real-time remote alarm information map and historical telemetry alarm information query
The parameter meter reading function mainly queries the electric parameters of the low-voltage outlet circuits, and has the functions of data export and report printing. The report queries the electrical parameters of the low-voltage loops of the incoming and outgoing lines, including: three-phase current, active power, and active power. The loop name of the report is associated with the database, which is convenient for the user to modify the loop name. See Figure (4).
Figure (4) Parameter reading
The power consumption report function can select the time period for query, support the electricity cumulative query for any time period, and have the functions of data export and report printing. Provide accurate and reliable energy reports for duty personnel. The loop name of the report is associated with the database, which is convenient for the user to modify the loop name, and also sets the multi-rate meter reading. As shown in the figure below, the precise power consumption of each power distribution circuit in a certain period of time, the user can directly print the report, and can save to other locations in EXCEL format. See Figure (5) and Figure (6).
Figure (5) Energy report
Figure (6) Multi-rate electricity report
The schematic diagram of the system communication structure mainly shows the networking structure of the system. The system adopts a layered distributed structure and monitors the communication status of the interval layer devices. Red indicates normal communication and green indicates communication failure. See Figure (7).
Figure (7) Schematic diagram of system communication structure
The load trend curve interface can be used to visually check the load operation of the loop. View real-time and historical trend curves, click the corresponding button or menu item on the screen to complete the corresponding function switching; help users to enter the trend analysis and fault recall, with curve printing function. Provides intuitive and convenient software support for analyzing the health of the entire system. See picture (8).
Figure (8) trend graph
The air compressor curve interface can intuitively view the loop load curves of five air compressors, and compare the curves of five air compressors with curve printing function. Provides intuitive and convenient software support for analyzing the operating conditions of air compressor power consumption. See Figure (9).
Figure (9) Air compressor curve
In the limit setting interface, the upper and lower limits of the alarm can be customized according to the site requirements, including the current, voltage, power, and power factors. The setting is updated in real time, and the software does not need to be restarted, which is convenient, fast, flexible and reliable, and provides intuitive and convenient software support for subsequent users to manage power supply and distribution conveniently. See Figure (10).
Figure (10) limit setting diagram
4 Conclusion
With the development of society and the wide application of electric power, the power monitoring system has become an inevitable choice for large-scale multi-substation users such as key projects, landmark buildings/large public facilities throughout the country. The Acrel-2000 power monitoring system introduced in this paper In the application of Nexteer Automotive Systems (Suzhou) Co., Ltd., real-time monitoring and power management of the power supply of the low-voltage distribution circuit of the substation can be realized, which not only can display the power consumption of the circuit, but also has the function of network communication, and can be used with the industry. The network switch, serial server, computer and other components constitute a power monitoring system, which facilitates the remote management of the personnel on duty in the substation, which is conducive to saving the time of meter reading and bringing information into power distribution monitoring. The system realizes the analysis and processing of the collected data, displays the running status of each distribution circuit in the substation in real time, and has pop-up alarm dialog box and voice prompt for the closing and closing of the load, and generates various energy reports, analysis curves, Graphics, etc., facilitate remote meter reading and analysis and research of electrical energy. The system is safe, reliable and stable, and provides a reliable and reliable basis for the users of the substation to solve the problem of electricity consumption, and has achieved good social benefits. [2]
references:
[1]. Ren Zhicheng Zhou Zhong. Principles and Application Guidelines of Power Electrical Measurement Digital Instrumentation [M]. Beijing. China Electric Power Press. 2007. 4
[2]. Zhou Zhongbian. Smart grid customer power monitoring and power management system product selection and solution [M]. Beijing. Mechanical Industry Press. 2011.10
About the Author:
Yang Junjun, female, undergraduate. Position: Now working for Ankerui Electric Co., Ltd.
Contact phone, mobile phone, QQ
Http://news.chinawj.com.cn Editor: (Hardware Business Network Information Center) http://news.chinawj.com.cn
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