Pre-mixed concrete multi-station remote centralized control system and control method

Abstract

The present application relates to the technical field of remote control, in particular to a ready-mixed concrete multi-station remote centralized control system and a control method, the control system comprising a control node arranged at each production line of a mixing station; a remote centralized control module comprising an engineer station computer and n control units, each control unit being used to control the control nodes of at least two production lines; a communication module used to communicatively connect the control nodes arranged in the mixing station in a region to the same network to realize collaborative control of multiple control nodes; the remote centralized control module and the control nodes arranged at the production lines in the mixing station perform data interaction through the communication module, and the engineer station computer uniformly manages and schedules the control units and the control nodes to dynamically manage and schedule the collaborative production of any two production lines in the region. The present application realizes collaborative production of multiple mixing stations, optimizes resource allocation and production scheduling, improves the working environment, saves costs and improves production efficiency.

Description

Technical Field

[0001] This invention relates to the field of remote control technology, specifically to a remote centralized control system and control method for multiple premixed concrete stations. Background Technology

[0002] Currently, the overall demand in the concrete industry is weak, with overcapacity and insufficient operating rates, leading to a sharp decline in the production profits of concrete companies. Limited production demand requires the full workforce, resulting in increasingly high labor costs. This not only wastes human resources but also makes companies unprofitable. The main problems are as follows:

[0003] 1. Each batching plant in a concrete production enterprise operates independently, lacking coordinated production. Some batching plants are fully booked, while others are scattered, resulting in a serious imbalance in production.

[0004] 2. The inability to flexibly arrange production based on transportation distance between different mixing plants and the inability to share vehicles result in a huge waste of transportation costs and reduced production efficiency;

[0005] 3. Each batching plant operates independently, organizes production, and has inconsistent quality standards and operating procedures, resulting in differences in concrete quality;

[0006] 4. Each production line is equipped with one operator, so n production lines require n operators. Even with reduced output, the number of operators remains the same, leading to increased labor costs and reduced profits. Therefore, resource reallocation is urgently needed. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a remote centralized control system and control method for multiple stations of ready-mixed concrete.

[0008] This invention is achieved through the following technical solution: The multi-station remote centralized control system for ready-mixed concrete includes:

[0009] Control nodes are set up at each production line of the mixing plant;

[0010] The remote centralized control module includes an engineer station computer and n control units, each of which controls the control nodes of at least two production lines;

[0011] The communication module is used to connect the control nodes deployed in the mixing plant within the region to the same network, enabling collaborative control of multiple control nodes;

[0012] The remote centralized control module interacts with the control nodes of the production lines deployed in the mixing plant through a communication module. The engineer station computer performs unified management and scheduling of the control units and control nodes, and dynamically manages and schedules any two production lines in the area to produce collaboratively.

[0013] The remote centralized control module interacts with m production lines of multiple mixing plants through a communication module. The engineer station computer manages and schedules the control unit and control node in a unified manner, enabling the arbitrary combination of two production lines from different mixing plants to produce for a designated control unit.

[0014] Preferably, each control unit includes one control computer, one video monitoring computer, and two network button boxes.

[0015] Preferably, each control node includes a production computer, n cameras, and one network button box.

[0016] Preferably, the engineer station computer provides WebService services for the control unit and control node, and Socket remote communication services for the network button box of the control unit and the network button box of the control node.

[0017] Furthermore, this application proposes a remote centralized control method for multiple ready-mixed concrete stations, applied to the aforementioned remote centralized control system for multiple ready-mixed concrete stations, comprising the following steps:

[0018] S1. The engineering workstation computer manages each control node, assigns a unique production line identifier to each control node, receives the periodic status information of the control node and feeds back the control identifier of the control unit assigned to that control node, monitors the network connection status, and alarms if there is an abnormality.

[0019] S2. The engineering workstation computer manages each control unit, assigns a unique control identifier to each control unit, verifies its permissions and issues production line configurations, receives periodic interactive data from the control unit, monitors network connection status, and alarms if there is an abnormality.

[0020] S3. The engineering workstation computer manages the video monitoring machine corresponding to each control unit. The video monitoring machine shares the control identifier of the control unit, pushes the periodic monitoring status, and issues production line monitoring configuration and work instructions after verification by the engineering workstation computer.

[0021] S4. When the control unit is online and the control node to be assigned is online but not in production, the engineer station computer assigns a control node to the control unit to prepare for concrete production.

[0022] Preferably, step S1 includes the following sub-steps:

[0023] S1-1. Assign a unique production line authorization code to each control node as a production line identifier. Based on the assigned production line authorization code, the control node calls the WebService interface provided by the engineer station computer to periodically push the alarm and production status of the corresponding control node to the engineer station computer. The engineer station computer returns the control authorization code assigned to a certain control unit. If no code is assigned, it returns 0.

[0024] S1-2. The engineer station computer establishes a network connection with the network button box of each control node, judges the network connection status in real time, and displays an alarm on the engineer station computer when the network connection is abnormally disconnected.

[0025] Preferably, step S2 includes the following sub-steps:

[0026] S2-1. Assign a unique control authorization code to each control unit as a control identifier. Based on the assigned control authorization code, the control unit calls the WebService interface provided by the engineering station computer to complete the verification of the operator list and the login control unit software permissions.

[0027] S2-2. After the control unit successfully logs in, it calls the WebService interface based on the control authorization code to obtain information on two control nodes from the engineer station computer. After successfully obtaining the control node information, the control unit establishes a connection with the control node of the production line and prepares to start concrete production.

[0028] S2-3. During operation, the control unit calls the WebService interface to periodically push the communication alarm status between the control unit and each control node, the current operator, the production volume after going online, and the running time after going online to the engineering station computer. The engineering station computer verifies the validity of the control unit and returns the production line authorization codes of the two control nodes to it. When the production line authorization code of the control node changes, the control unit will take the current control node offline and complete the connection and online operation of the new control node.

[0029] S2-4. The engineering station computer establishes a network connection with the network button box of each control unit, judges the network connection status in real time, and displays an alarm on the engineering station computer when the network connection is abnormally disconnected.

[0030] Preferably, the information of the control node in S2-2 includes the production line name, production line authorization code, connection IP, connection port, and sequence number information.

[0031] Preferably, step S3 includes the following sub-steps:

[0032] S3-1. The video surveillance unit relies on its corresponding control unit and shares the same control authorization code with the control unit.

[0033] S3-2. Based on the assigned control authorization code, the video monitoring unit calls the WebService interface provided by the engineering station computer to periodically push the monitoring alarm status of the control node and the control node serial number to the engineering station computer. The engineering station computer verifies the validity of the video monitoring unit and returns the production line number, the relevant camera information of the control node, and the flags that need to be displayed or turned off.

[0034] Preferably, step S4 includes the following sub-steps:

[0035] S4-1, The engineer station computer can arbitrarily combine different production lines of different mixing plants and assign them to the control unit. The control node to be assigned is online and not in production.

[0036] S4-2. The engineering workstation computer allocates video monitoring information to the control unit and notifies the video monitoring machine to turn on the real-time monitoring video corresponding to the control node. If an alarm status is received from the video monitoring machine, the allocation of the control node fails.

[0037] S4-3. The engineer station computer matches the network button box to the control unit. It combines the production line authorization code and the control authorization code into a unique combination authorization code by combining the high and low bits. The combination authorization code is then sent to the pairing button box. At the same time, the IP address of the other party's button box is sent to the network button box of the same group to complete the pairing of the network button boxes. If the sending fails, the allocation of the control node fails.

[0038] S4-4. After the above steps are successfully completed, notify the control unit that the control node allocation has been completed and concrete production is ready.

[0039] Compared with the prior art, the beneficial effects of the present invention are:

[0040] Achieve production collaboration and optimized resource allocation. Through the cooperation of remote centralized control and communication modules, multiple mixing plants in the region are incorporated into a unified network management system. The engineering workstation computer can arbitrarily combine and schedule the production lines of different mixing plants, solving the problem of uneven production caused by the independent operation of each mixing plant, making full use of idle capacity, and improving the overall capacity utilization rate.

[0041] Costs have been reduced and economic efficiency improved. On the one hand, a single control unit can control two production lines simultaneously, significantly reducing the number of operators and lowering labor costs. On the other hand, based on unified scheduling, production at mixing plants closer to the construction site can be prioritized, enabling vehicles to share resources across stations, reducing transportation distances and lowering transportation costs.

[0042] Ensuring the stability of concrete quality. This application utilizes unified operating standards and quality control logic, with a remote centralized control module to standardize and manage the production process of each production line. This avoids inconsistencies in quality standards caused by independent production at each mixing plant, improves concrete quality consistency, and meets the stringent quality requirements of engineering construction. Based on unified production control, unified operating standards, and unified business management, resource allocation and production scheduling are optimized, and the working environment is improved.

[0043] This application enhances production efficiency and management convenience. Based on a remote centralized control mode, it integrates data from various mixing plant operations, enabling cross-regional production consolidation and unified business management. This results in faster production scheduling response and improved overall production efficiency. Simultaneously, the engineering workstation computer can monitor the production line, control units, and video surveillance status in real time, promptly alerting staff to any abnormalities, reducing management complexity and improving operational convenience. Attached Figure Description

[0044] Figure 1 This is a block diagram of the control system structure of this application;

[0045] Figure 2 This is a flowchart of the control method of this application. Detailed Implementation

[0046] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0047] Example 1

[0048] Reference Figure 1 A multi-station remote centralized control system for ready-mixed concrete includes:

[0049] Control nodes are set up on each production line of the mixing plant; specifically, in the m production lines of multiple mixing plants, each production line corresponds to a control node, which performs production control and monitoring of the production line.

[0050] The remote centralized control module includes an engineer station computer and n control units. Each control unit is used to control the control nodes of at least two production lines, thereby enabling one control unit to control at least two production lines to operate online simultaneously.

[0051] The communication module connects the control nodes deployed within the mixing plants in the region to the same network, enabling collaborative control among multiple control nodes. The communication module connects the mixing plants in the region to the same network, enabling collaborative production among multiple mixing plants, streamlining data across business processes, and achieving cross-regional integration. Furthermore, in this embodiment, the communication module utilizes existing technology to establish a secure and reliable dedicated data line or VPN virtual network, thereby connecting all mixing plants within the enterprise in the region to the same network.

[0052] The remote centralized control module interacts with the control nodes deployed on the production lines within the mixing plant via a communication module. The engineer station computer manages and schedules the control units and control nodes in a unified manner, dynamically managing and scheduling any two production lines within the area to produce collaboratively. Thus, the engineer station computer's unified management and scheduling of control units and control nodes enables the allocation of production from control nodes of any two production lines from different mixing plants to a designated control unit.

[0053] In this embodiment, each control unit includes one control computer, one video monitoring computer, and two network button boxes. Each control node includes a production computer, n cameras, and one network button box.

[0054] The engineering workstation computer provides WebService services for the control unit and control node, and also provides Socket remote communication services for the network button box of the control unit and the network button box of the control node.

[0055] Example 2

[0056] Reference Figure 2 Based on Example 1, this example proposes a remote centralized control method for multiple ready-mixed concrete stations, including the following steps:

[0057] S1. The engineering workstation computer manages each control node, assigns a unique production line identifier to each control node, receives the periodic status information of the control node and feeds back the control identifier of the control unit assigned to that control node, monitors the network connection status, and alarms if there is an abnormality.

[0058] Specifically, S1 includes the following sub-steps:

[0059] S1-1. Assign a unique production line authorization code to each control node as a production line identifier. Based on the assigned production line authorization code, the control node calls the WebService interface provided by the engineer station computer to periodically push the alarm and production status of the corresponding control node to the engineer station computer. The engineer station computer returns the control authorization code assigned to a certain control unit. If no code is assigned, it returns 0.

[0060] S1-2. The engineer station computer uses Socket remote communication technology to establish a network connection with the network button box of each control node, and judges the network connection status in real time. When the network connection is abnormally disconnected, an alarm is displayed on the engineer station computer.

[0061] S2. The engineering workstation computer manages each control unit, assigns a unique control identifier to each control unit, verifies its permissions and issues production line configurations, receives periodic interactive data from the control unit, monitors network connection status, and issues an alarm if there is an abnormality.

[0062] Furthermore, step S2 includes the following sub-steps:

[0063] S2-1. Assign a unique control authorization code as a control identifier to each control unit. Based on the assigned control authorization code, the control unit calls the WebService interface provided by the engineering station computer to complete the verification of the operator list and the login control unit software permissions.

[0064] S2-2. After the control unit successfully logs in, it calls the WebService interface based on the control authorization code to obtain information about two control nodes from the engineer station computer. After successfully obtaining the control node information, the control unit establishes a connection with the control node of the production line and prepares to start concrete production.

[0065] In this embodiment, the information of the control node in S2-2 includes the production line name, production line authorization code, connection IP, connection port, and sequence number information.

[0066] S2-3. During operation, the control unit calls the WebService interface to periodically push the communication alarm status between the control unit and each control node, the current operator, the production volume after going online, and the running time after going online to the engineering station computer. The engineering station computer verifies the validity of the control unit and returns the production line authorization codes of the two control nodes to it. When the production line authorization code of the control node changes, the control unit will take the current control node offline and complete the connection and online operation of the new control node.

[0067] S2-4. The engineering station computer uses Socket remote communication technology to establish a network connection with the two network button boxes of each control unit, and judges the network connection status in real time. When the network connection is abnormally disconnected, an alarm is displayed on the engineering station computer.

[0068] S3. The engineering workstation computer manages the video monitoring machine corresponding to each control unit. The video monitoring machine shares the control identifier of the control unit, pushes the periodic monitoring status, and issues production line monitoring configuration and work instructions after verification by the engineering workstation computer.

[0069] Furthermore, step S3 includes the following sub-steps:

[0070] S3-1 The video surveillance unit relies on its corresponding control unit and shares the same control authorization code with the control unit.

[0071] S3-2. Based on the assigned control authorization code, the video monitoring unit calls the WebService interface provided by the engineering station computer to periodically push the monitoring alarm status of the control node and the control node serial number to the engineering station computer. The engineering station computer verifies the validity of the video monitoring unit and returns the production line number, the relevant camera information of the control node, and the flags that need to be displayed or turned off.

[0072] S4. When the control unit is online and the control node to be assigned is online but not in production, the engineer station computer assigns a control node to the control unit to prepare for concrete production.

[0073] Furthermore, step S4 includes the following sub-steps:

[0074] S4-1. The engineering workstation computer can arbitrarily combine different production lines of different mixing plants according to the actual situation and assign them to the control unit. The control node to be assigned must be online and not in production before it can be assigned.

[0075] S4-2. The engineering workstation computer allocates video monitoring information to the control unit and notifies the video monitoring machine to enable the real-time monitoring video corresponding to the control node. If an alarm status is received from the video monitoring machine, the allocation of the control node fails.

[0076] S4-3. The engineer station computer matches the network button box to the control unit. It combines the production line authorization code and the control authorization code into a unique combination authorization code by combining the high and low bits. The combination authorization code is then sent to the pairing button box. At the same time, the IP address of the other party's button box is sent to the network button box of the same group to complete the pairing of the network button boxes. If the sending fails, the allocation of the control node fails.

[0077] S4-4. After the above steps are successfully completed, notify the control unit that the control node allocation has been completed and concrete production is ready.

[0078] Example 3

[0079] Taking four mixing plants as an example, each mixing plant corresponds to two production lines, two dispatchers, and ten transport vehicles. Each production line has at least two operators working in two shifts. The annual income of dispatchers and operators is calculated to be 80,000 yuan.

[0080] In terms of labor costs, after using the control system and control method described in Example 1, the dispatcher can centrally dispatch the four mixing plants. Based on two shifts, only two dispatchers are needed, which saves six dispatchers. Moreover, one operator can operate two production lines at the same time. With the four mixing plants and a total of eight production lines working in two shifts, eight operators can also be saved.

[0081] The comparison of labor costs between the prior art and this application is shown in Table 1.

[0082] Table 1. Comparison of Labor Costs between Prior Art and This Application

[0083]

[0084] In terms of transportation costs, all mixing plants are scheduled uniformly, with shared vehicles arranged nearby. Assuming that each vehicle saves 10 kilometers per round trip after being arranged nearby, and calculating 10 trips per day, then 100 kilometers can be saved per day. Assuming each vehicle uses 10 liters of diesel per 100 kilometers at a price of 7 yuan per liter, the annual cost saving per vehicle is: 12 * 30 * 100 * 10 / 100 * 7 = 25,200 yuan. Therefore, the total mileage saved annually for all vehicles at the four mixing plants is: 40 * 100 * 365 = 1,460,000 kilometers, and the total cost saving is: 25,200 * 40 = 1,008,000 yuan.

[0085] In terms of efficiency, assuming a single batching plant produces 300,000 cubic meters of concrete annually with a profit of 20 yuan per cubic meter, and considering the control system and method proposed in this application, all batching plants will have unified production scheduling, with vehicles arranged nearby, and rapid continuous production efficiency increased by 15%. Therefore, the annual revenue could increase by 300,000 * 4 * 20 * 15% = 3.6 million yuan.

[0086] As can be seen, this application enables operators to not only arbitrarily schedule and combine different production lines at different mixing plants, but also to allow one person to control any number of lines for production, enabling enterprises to achieve unified production control, unified operating standards, unified business management, optimize resource allocation and production scheduling, improve the working environment, save labor and transportation costs, and improve production efficiency.

[0087] The above description is merely an optional embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the content of the present invention under the concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A remote centralized control system for multiple stations of ready-mixed concrete, characterized in that, include: Control nodes are set up at each production line of the mixing plant; The remote centralized control module includes an engineer station computer and n control units, each of which controls the control nodes of at least two production lines; The communication module is used to connect the control nodes deployed in the mixing plant within the region to the same network, enabling collaborative control of multiple control nodes; The remote centralized control module interacts with the control nodes of the production line deployed in the mixing plant through a communication module. The engineer station computer performs unified management and scheduling of the control unit and control node, and dynamically manages and schedules any two production lines in the area to produce collaboratively. The control method of the multi-station remote centralized control system for ready-mixed concrete includes the following steps: S1. The engineering workstation computer manages each control node, assigns a unique production line identifier to each control node, receives the periodic status information of the control node and feeds back the control identifier of the control unit assigned to that control node, monitors the network connection status, and alarms if there is an abnormality; S1 includes the following sub-steps: S1-1. Assign a unique production line authorization code to each control node as a production line identifier. Based on the assigned production line authorization code, the control node calls the WebService interface provided by the engineer station computer to periodically push the alarm and production status of the corresponding control node to the engineer station computer. The engineer station computer returns the control authorization code assigned to a certain control unit. If no code is assigned, it returns 0. S1-2. The engineering station computer establishes a network connection with the network button box of each control node, and judges the network connection status in real time. When the network connection is abnormally disconnected, an alarm is displayed on the engineering station computer. S2. The engineering workstation computer manages each control unit, assigns a unique control identifier to each control unit, verifies its permissions and issues production line configurations, receives periodic interactive data from the control units, monitors network connection status, and alarms if any abnormality is detected; S2 includes the following sub-steps: S2-1. Assign a unique control authorization code to each control unit as a control identifier. Based on the assigned control authorization code, the control unit calls the WebService interface provided by the engineer station computer to complete the verification of the operator list and the permission to log in to the control unit. S2-2. After the control unit successfully logs in, it calls the WebService interface based on the control authorization code to obtain information on two control nodes from the engineer station computer. After successfully obtaining the control node information, the control unit establishes a connection with the control node of the production line and prepares to start concrete production. S2-3. During operation, the control unit calls the WebService interface to periodically push the communication alarm status between the control unit and each control node, the current operator, the production volume after going online, and the running time after going online to the engineering station computer. The engineering station computer verifies the validity of the control unit and returns the production line authorization codes of the two control nodes to it. When the production line authorization code of the control node changes, the control unit will take the current control node offline and complete the connection and online operation of the new control node. S2-4. The engineering station computer establishes a network connection with the network button box of each control unit, judges the network connection status in real time, and displays an alarm on the engineering station computer when the network connection is abnormally disconnected. S3. The engineering workstation computer manages the video monitoring unit corresponding to each control unit. The video monitoring unit shares the control identifier of the control unit, pushes the periodic monitoring status, and issues production line monitoring configuration and work instructions after verification by the engineering workstation computer. S3 includes the following sub-steps: S3-1. The video surveillance unit relies on its corresponding control unit and shares the same control authorization code with the control unit. S3-2. Based on the assigned control authorization code, the video monitoring unit calls the WebService interface provided by the engineering station computer to periodically push the monitoring alarm status of the control node and the control node serial number to the engineering station computer. The engineering station computer verifies the validity of the video monitoring unit and returns the production line number, the relevant camera information of the control node, and the flag that needs to be displayed or turned off. S4. When the control unit is online and the control node to be assigned is online but not in production, the engineer station computer assigns a control node to the control unit to prepare for concrete production. S4 includes the following sub-steps: S4-1, The engineering workstation computer can arbitrarily combine different production lines of different mixing plants and assign them to the control unit. The control node to be assigned is online and not in production. S4-2. The engineering workstation computer allocates video monitoring information to the control unit and notifies the video monitoring machine to turn on the real-time monitoring video corresponding to the control node. If an alarm status is received from the video monitoring machine, the allocation of the control node fails. S4-3. The engineer station computer matches the network button box to the control unit. It combines the production line authorization code and the control authorization code into a unique combination authorization code by combining the high and low bits. The combination authorization code is then sent to the pairing button box. At the same time, the IP address of the other party's button box is sent to the network button box of the same group to complete the pairing of the network button boxes. If the sending fails, the allocation of the control node fails. S4-4: Notify the control unit that the control node allocation has been completed and that concrete production is ready.

2. The pre-mixed concrete multi-station remote centralized control system according to claim 1, characterized in that, Each control unit includes one control computer, one video surveillance computer, and two network button boxes.

3. The pre-mixed concrete multi-station remote centralized control system according to claim 2, characterized in that, Each control node includes a production computer, n cameras, and one network button box.

4. The pre-mixed concrete multi-station remote centralized control system according to claim 3, characterized in that, The engineering workstation computer provides WebService services for the control unit and control node, and also provides Socket remote communication services for the network button box of the control unit and the network button box of the control node.

5. The remote centralized control system for multi-station ready-mixed concrete according to claim 1, characterized in that, The information of the control node in S2-2 includes the production line name, production line authorization code, connection IP, connection port, and sequence number information.

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