Equipment inspection tracking system and real-time monitoring method for inspection personnel

Abstract

The present invention relates to an equipment spot inspection tracking system and a real-time monitoring method for spot inspection personnel, comprising: a PLC controller; a plurality of infrared sensors arranged at the entrance of each spot inspection area, which are connected to the PLC controller; an audible and visual alarm, which is connected to the PLC controller and arranged in a duty room; an industrial computer, which is connected to the PLC controller, and a timing and timeout execution unit is arranged in the industrial computer. When the spot inspection personnel pass through two adjacent infrared sensors, the industrial computer is used to receive the passing signal, the timing unit is used to calculate the time interval between the two signals, and the timeout execution unit is used to judge whether the spot inspection personnel has timed out. If the standard time is exceeded, the audible and visual alarm located in the duty room will sound an alarm, indicating that the spot inspection area is abnormal, and the duty personnel will immediately contact the spot inspection personnel for confirmation; if it is not exceeded, the spot inspection of the subsequent areas will be continued until it is finished, which can effectively avoid the problem of damage expansion and low spot inspection efficiency caused by abnormalities of the spot inspection personnel that are not discovered by anyone.

Description

Technical Field

[0001] The present invention relates to the technical field of safe production, and in particular to an equipment spot inspection tracking system and a real-time monitoring method for spot inspection personnel. Background Art

[0002] In a foundry, after a certain period of operation, the relevant equipment in the entire electric furnace area needs to be inspected to confirm whether the various indicators of the equipment are in good condition, so as to ensure the subsequent normal production progress and prevent the occurrence of safety accidents.

[0003] However, the autonomous inspection of equipment in this area generally involves a wide area with a complex environment and certain safety risks in equipment operation. If the operator's single-person inspection process is not controlled and any abnormal situation cannot be discovered in time during the inspection, a single-person inspection or a danger during the operation will not be discovered in time, which will lead to the expansion of injuries. For example, an ordinary electric furnace area is generally composed of seven one-way connected equipment and areas in sequence: "vertical shaft-consumable oxygen gun-valve room-high and low voltage electrical room-vibrating feeder-stand-molten iron car". The inspection personnel enter from the entrance of the first inspection area and inspect the equipment in each area in turn until they leave the last inspection area and complete the inspection of the entire area. In the actual inspection process, there is often a phenomenon that the inspection personnel stay in some remote areas to play with their mobile phones, which greatly affects safety and work efficiency. Summary of the invention

[0004] To this end, the technical problem to be solved by the present invention is to overcome the problem in the prior art that operators cannot monitor the inspection positions and inspection durations of multiple devices in real time when performing inspection operations.

[0005] In order to solve the above technical problems, the present invention provides an equipment inspection and tracking system, comprising:

[0006] A PLC controller including an input terminal and an output terminal;

[0007] A plurality of infrared sensors, which are respectively connected to the input end of the PLC controller, and the plurality of infrared sensors are respectively arranged at the entrance of each inspection area, and the infrared sensors are used to transmit the passing signal of the inspection personnel to the PLC controller;

[0008] An audible and visual alarm is connected to the output end of the PLC controller, and the audible and visual alarm is arranged in the duty room;

[0009] An industrial computer connected to the PLC controller, wherein a timing unit and a timeout execution unit are provided in the industrial computer. When the inspection personnel pass through two adjacent infrared sensors, the industrial computer is used to receive a passing signal, the timing unit is used to calculate the time interval between the two signals, and the timeout execution unit is used to determine whether the inspection personnel has exceeded the time limit;

[0010] When the inspection personnel enters the second inspection area from the entrance of the first inspection area, the industrial computer determines whether the inspection personnel's stay time in the first inspection area exceeds the set time of the single inspection area based on the two received pass signals. If exceeded, the industrial computer controls the sound and light alarm to work via the PLC controller. If not exceeded, the next inspection area is continued to be judged until the last inspection area. When judging the last inspection area, the industrial computer determines whether it exceeds the set time of the single inspection area based on the time the inspection personnel enters the last inspection area and the stay time when returning to the duty room. If not exceeded, the inspection work is completed. If exceeded, the industrial computer controls the sound and light alarm to work via the PLC controller.

[0011] In one embodiment of the present invention, the industrial computer is provided with a spot inspection start button and a spot inspection end button.

[0012] In one embodiment of the present invention, the industrial computer includes a human-computer interaction screen, and the inspection start button and the inspection end button are both arranged on the human-computer interaction screen.

[0013] In one embodiment of the present invention, a spot inspection circuit diagram is also provided on the human-computer interaction screen, and the spot inspection circuit diagram includes a plurality of indicator light strips, and the plurality of indicator light strips correspond to the respective spot inspection areas.

[0014] In one embodiment of the present invention, a timeout alarm display area is provided on the human-computer interaction screen.

[0015] In one embodiment of the present invention, a QR code for reporting inspection problems is provided on the human-computer interaction screen.

[0016] In another embodiment of the present invention, the infrared sensors are respectively arranged at the entrance and exit of each inspection area.

[0017] The present invention also provides a method for real-time monitoring of inspection personnel, which utilizes the equipment inspection tracking system as described above to monitor the inspection personnel in real time, comprising the following steps:

[0018] (1) Read the time interval from the time the inspector enters the previous inspection area to the time he leaves the area;

[0019] (2) The inspection time of personnel in each inspection area is judged in turn. If the current inspection area exceeds the standard time, an alarm is issued. If it does not exceed the time limit, the next inspection area is judged;

[0020] (3) The on-duty personnel shall make telephone contact with the personnel who are performing inspection operations according to the alarm instructions.

[0021] In another embodiment of the present invention, the alarm system sets different standard detection times according to the length of the inspection area.

[0022] The above technical solution of the present invention has the following advantages compared with the prior art:

[0023] The equipment inspection and tracking system and the real-time monitoring method for inspection personnel described in the present invention install infrared sensors at the entrance of each inspection area, and the signal is connected to the PLC controller to monitor the dynamic real-time of the inspection personnel. The PLC controller transmits the point information to the industrial computer and executes the instructions issued by the industrial computer. The industrial computer times the stay time of the inspection personnel in each inspection area through the system program. If the standard time is exceeded, the sound and light alarm in the duty room will sound an alarm, indicating that the inspection area is abnormal. The duty personnel immediately contact the inspection personnel for confirmation, which effectively avoids the problem of increased damage and low inspection efficiency caused by abnormalities of the inspection personnel without anyone noticing. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to make the content of the present invention more clearly understood, the present invention is further described in detail below according to specific embodiments of the present invention in conjunction with the accompanying drawings, wherein

[0025] Figure 1 This is a schematic diagram of the electrical connection structure of the equipment inspection and tracking system of the present invention;

[0026] Figure 2 It is the display content of the human-computer interaction screen on the industrial computer in the equipment inspection and tracking system of the present invention.

[0027] Explanation of the markings in the specification: 1. PLC controller; 2. Infrared sensor; 3. Sound and light alarm; 4. Industrial computer; 410. Human-computer interaction screen; 411. Inspection start button; 412. Inspection end button; 413. Indicator light strip; 414. Timeout alarm display area; 415. QR code for filling in inspection problems; A. First inspection area; N. Last inspection area; a. Infrared sensor of the first inspection area; n. Infrared sensor of the last inspection area. DETAILED DESCRIPTION

[0028] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments so that those skilled in the art can better understand the present invention and implement it, but the embodiments are not intended to limit the present invention.

[0029] Example 1

[0030] Reference Figure 1 to Figure 2 As shown, the present invention provides an equipment inspection and tracking system, comprising:

[0031] A PLC controller 1, comprising an input terminal and an output terminal;

[0032] A plurality of infrared sensors 2, which are respectively connected to the input end of the PLC controller 1, and the plurality of infrared sensors 2 are respectively arranged at the entrance of each inspection area, and the infrared sensor is used to transmit the passing signal of the inspection personnel to the PLC controller 1;

[0033] An audible and visual alarm 3 is connected to the output end of the PLC controller 1 and is arranged in the duty room;

[0034] The industrial computer 4 is connected to the PLC controller 1. A timing unit and a timeout execution unit are provided in the industrial computer 4. When the inspection personnel pass through two adjacent infrared sensors 2, the industrial computer 4 is used to receive a passing signal, the timing unit is used to calculate the time interval between the two signals, and the timeout execution unit is used to determine whether the inspection personnel has timed out.

[0035] When the inspection personnel enters the second inspection area from the entrance of the first inspection area, the industrial computer 4 determines whether the inspection personnel's stay time in the first inspection area exceeds the set time of the single inspection area based on the two received pass signals. If exceeded, the industrial computer 4 controls the sound and light alarm 3 to work via the PLC controller 1. If not exceeded, the next inspection area is continued to be judged until the last inspection area N. When judging the last inspection area N, the industrial computer 4 determines whether it exceeds the set time of the single inspection area based on the time the inspection personnel enters the last inspection area N and the stay time returning to the duty room. If not exceeded, the inspection work is completed. If exceeded, the industrial computer 4 controls the sound and light alarm 3 to work via the PLC controller 1.

[0036] The equipment inspection and tracking system and the real-time monitoring method for inspection personnel described in the present invention install infrared sensors 2 at the entrance of each inspection area, and the signal is connected to the PLC controller 1 to monitor the dynamic real-time of the inspection personnel. The PLC controller 1 transmits the point information to the industrial computer 4 and executes the instructions issued by the industrial computer 4. The industrial computer 4 times the stay time of the inspection personnel in each inspection area through the system program. If the standard time is exceeded, the sound and light alarm 3 located in the duty room will sound an alarm, indicating that the inspection area is abnormal. The duty personnel immediately contact the inspection personnel for confirmation, which effectively avoids the problem of increased damage and low inspection efficiency caused by abnormalities of the inspection personnel that are not discovered.

[0037] Specifically, infrared sensors are installed at the entrance of each inspection area. When the operator passes through the entrance of the first inspection area A, the infrared sensor at the entrance of the area sends a signal to the PLC controller 1. The PLC controller 1 transmits the detection signal to the industrial computer 4 according to the built-in program. The timing unit of the industrial computer 4 records the time of the point. When the inspection personnel walk out of the first inspection area A and pass through the entrance of the second inspection area, the infrared sensor 2 and the PLC controller 1 execute the same instruction. The timing unit of the industrial computer 4 records the time of the second point and judges it through the timeout execution unit. The timeout execution unit is a receiving and executing program, which first sets a standard time and sets the time given by the timing unit. The time interval between the previous and next points is obtained by dividing the standard time by the time interval to obtain a ratio. If the ratio is greater than 1, it is considered qualified, that is, the inspection personnel's stay in the area has not exceeded the time limit. The timing unit and the timeout execution unit start to judge the next inspection area until the last inspection area N is completed. It should be noted that the exit of the last inspection area N should also be equipped with an infrared sensor 2 to realize the termination timing of the area; if the ratio is less than 1, it is considered to be a timeout. At this time, the timeout execution unit of the industrial computer 4 gives the PLC controller 1 an alarm instruction, and the PLC controller 1 acts on the sound and light alarm 3 to power on the alarm. The personnel in the duty room can get the message in time and contact the on-site personnel, which is very practical and efficient.

[0038] Furthermore, the industrial computer 4 is provided with a spot inspection start button 411 and a spot inspection end button 412 .

[0039] Specifically, when the operator sets out from the duty room, he first presses the inspection start button 411 to start the entire system. At this time, the infrared sensor 2, PLC controller 1 and industrial computer 4 start working. The inspection end button 412 serves as the end button of the entire system. If the exit of the last inspection area N is not equipped with a corresponding infrared sensor 2, then this end button is also the end timing point of the last inspection area N.

[0040] Furthermore, the industrial computer 4 includes a human-computer interaction screen 410 , and an inspection start button 411 and an inspection end button 412 are both arranged on the human-computer interaction screen 410 .

[0041] Specifically, the human-computer interaction screen 410 is presented in a simulated state in the duty room, and the inspection start button 411 and the inspection end button 412 can be set in a simulated state on the human-computer interaction screen 410. The operator can operate directly on the human-computer interaction screen 410 without adding additional buttons to interact with the system. At the same time, the human-computer interaction screen 410 can present corresponding images as needed, which is more intuitive and simpler to set up.

[0042] Furthermore, an inspection route diagram is also provided on the human-machine interaction screen 410 , and the inspection route diagram includes a plurality of indicator light strips 413 , and the plurality of indicator light strips 413 correspond to the inspection areas respectively.

[0043] Specifically, the inspection route map is to facilitate the on-duty personnel to monitor the dynamics of the current inspection personnel in real time, that is, where the current inspection personnel are located, such as Figure 2 As shown, the indicator light strip 413 is a simulation display. When the light strip is on, it means that the inspection personnel have normally completed the inspection of the previous inspection area and entered the next inspection area. It is very intuitive and truly realizes the real-time monitoring of the time and location of the inspection personnel.

[0044] Furthermore, a timeout alarm display area 414 is provided on the human-computer interaction screen 410 .

[0045] Specifically, the timeout alarm display area 414 is used in conjunction with the sound and light alarm 3, and the content can be edited to remind the on-duty personnel to better understand the timeout status of the current inspection personnel, such as the specific time of the timeout, and supplemented with eye-catching warning colors such as red.

[0046] Furthermore, a QR code 415 for reporting inspection problems is provided on the human-computer interaction screen 410 .

[0047] Specifically, after finishing the inspection, the inspection personnel can scan the inspection problem reporting QR code 415 on the human-machine interaction screen 410, and fill in the corresponding equipment inspection information to facilitate other personnel to understand the relevant equipment status in a timely manner.

[0048] Example 2

[0049] Reference Figure 1 As shown, infrared sensors 2 are respectively arranged at the entrance and exit positions of each inspection area.

[0050] Specifically, different reference times can be set according to the length of each inspection area, which is more in line with reality. At the same time, the time error when the previous inspection area reaches the infrared sensor 2 at the entrance of the next area should be considered and input into the program to reduce the occurrence of false alarms.

[0051] Example 3

[0052] The present invention also provides a method for real-time monitoring of inspection personnel, which utilizes the above-mentioned equipment inspection tracking system to monitor the inspection personnel in real time, comprising the following steps:

[0053] (1) Read the time interval from the time the inspector enters the previous inspection area to the time he leaves the area;

[0054] (2) The inspection time of personnel in each inspection area is judged in turn. If the current inspection area exceeds the standard time, an alarm is issued. If it does not exceed the time limit, the next inspection area is judged;

[0055] (3) The on-duty personnel shall make telephone contact with the personnel who are performing inspection operations according to the alarm instructions.

[0056] Furthermore, the alarm system sets different standard detection times according to the length of the inspection area.

[0057] Specifically, different standard inspection times are more in line with reality. Each inspection area should determine the appropriate time based on the average equipment inspection time and efficient working hours. At the same time, an alarm procedure should be set up to ensure that the on-duty personnel can continue with normal inspection of the next area after questioning the inspection personnel.

[0058] Obviously, the above embodiments are merely examples for clear explanation and are not intended to limit the implementation methods. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the implementation methods here. The obvious changes or modifications derived from them are still within the protection scope of the invention.

Claims

1. An equipment inspection and tracking system, characterized in that: include: A PLC controller including an input terminal and an output terminal; A plurality of infrared sensors, which are respectively connected to the input end of the PLC controller, and the plurality of infrared sensors are respectively arranged at the entrance of each inspection area, and the infrared sensors are used to transmit the passing signal of the inspection personnel to the PLC controller; An audible and visual alarm is connected to the output end of the PLC controller, and the audible and visual alarm is arranged in the duty room; An industrial computer connected to the PLC controller, wherein a timing unit and a timeout execution unit are provided in the industrial computer. When the inspection personnel pass through two adjacent infrared sensors, the industrial computer is used to receive a passing signal, the timing unit is used to calculate the time interval between the two signals, and the timeout execution unit is used to determine whether the inspection personnel has exceeded the time limit; When the inspection personnel enters the second inspection area from the entrance of the first inspection area, the industrial computer determines whether the inspection personnel's stay time in the first inspection area exceeds the set time of the single inspection area based on the two received pass signals. If exceeded, the industrial computer controls the sound and light alarm to work via the PLC controller. If not exceeded, the next inspection area is continued to be judged until the last inspection area. When judging the last inspection area, the industrial computer determines whether it exceeds the set time of the single inspection area based on the time the inspection personnel enters the last inspection area and the stay time when returning to the duty room. If not exceeded, the inspection work is completed. If exceeded, the industrial computer controls the sound and light alarm to work via the PLC controller.

2. The equipment inspection and tracking system according to claim 1, characterized in that: The industrial computer is provided with a spot inspection start button and a spot inspection end button.

3. The equipment inspection and tracking system according to claim 2 is characterized in that: The industrial computer comprises a human-computer interaction screen, and the inspection start button and the inspection end button are both arranged on the human-computer interaction screen.

4. The equipment inspection and tracking system according to claim 3 is characterized in that: The human-machine interaction screen is also provided with an inspection circuit diagram, which includes a plurality of indicator light strips, and the plurality of indicator light strips correspond to the inspection areas respectively.

5. The equipment inspection and tracking system according to claim 3 is characterized in that: A timeout alarm display area is provided on the human-computer interaction screen.

6. The equipment inspection and tracking system according to claim 3 is characterized in that: A QR code for reporting inspection problems is provided on the human-computer interaction screen.

7. The equipment inspection and tracking system according to claim 1, characterized in that: The infrared sensors are respectively arranged at the entrance and exit positions of each inspection area.

8. A method for real-time monitoring of inspection personnel, using the equipment inspection tracking system according to any one of claims 1 to 7 to monitor the inspection personnel in real time, characterized in that: The following steps are involved: Read the time interval from the time the inspector enters the previous inspection area to the time he leaves the area in sequence; The inspection time of personnel in each inspection area is judged in turn. If the current inspection area exceeds the standard time, an alarm is issued. If it does not exceed the time limit, the next inspection area is judged; The on-duty personnel will contact the personnel who are performing inspection operations according to the alarm instructions.

9. The method for real-time monitoring of inspection personnel according to claim 8, characterized in that: The equipment inspection and tracking system sets different standard inspection times according to the length of the inspection area.

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