Risk early warning system of industrial control equipment and early warning method thereof

Abstract

The invention discloses a risk early warning system for industrial control equipment and an early warning method thereof, and the system comprises a data collection module which is used for collecting the operation data of the industrial control equipment; the data transmission module is used for transmitting the data acquired by the acquisition module to the data processing module; the data processing module is used for storing and analyzing the transmitted operation data; the risk assessment module is used for carrying out risk assessment based on an analysis result of the data processing module and judging whether a potential risk exists or not; the early warning output module is used for sending early warning information to an operator and a management system when the potential risk is detected; and the visualization module is used for displaying the real-time operation state and early warning information of the equipment. According to the risk early warning system of the industrial control equipment and the early warning method thereof, the industrial control equipment is monitored in real time, potential risks can be found in time, and the processing speed and the early warning accuracy of the system are improved through integrated design of the data processing module and the risk assessment module.

Description

Technical Field

[0001] The present invention belongs to the field of industrial control equipment, and in particular relates to a risk early warning system and an early warning method for industrial control equipment. Background Art

[0002] In modern industrial processes, various industrial control equipment is widely used. Industrial control equipment refers to equipment and systems used in industrial production processes to monitor, control and adjust production or process parameters. These devices are usually used in automated production lines, factories and equipment to ensure the stability, efficiency and quality of the production process. The main functions of industrial control equipment include monitoring various parameters in the production process, collecting data, analyzing information, making decisions and executing control actions.

[0003] However, these devices may cause accidents due to malfunctions, harsh environments or improper operation, resulting in economic losses and safety hazards. Many risk warning systems currently on the market often have problems such as inaccurate warnings and long response times. Summary of the invention

[0004] The purpose of the present invention is to provide a risk early warning system and early warning method for industrial control equipment, which solves the problems in the background technology.

[0005] In order to achieve the above object, the present invention adopts the following technical solution: A risk early warning system for industrial control equipment, comprising: Data acquisition module, used to collect operating data of industrial control equipment; A data transmission module, used for transmitting the operation data collected by the data collection module to the data processing module; A data processing module, used to store and analyze the transmitted operation data; The risk assessment module is used to conduct risk assessment based on the analysis results of the data processing module to determine whether there are potential risks; The early warning output module is used to send early warning information to operators and management systems when potential risks are detected; Visualization module, used to display the real-time operation status and warning information of the equipment.

[0006] As a preferred technical solution of the present invention, the data acquisition module includes: Temperature sensor unit, used to measure temperature changes in key parts of industrial control equipment; Pressure sensor unit, used to measure pressure conditions inside or outside the equipment; Current sensor unit, used to measure the current consumption of the equipment, and determine whether the equipment has electrical faults or overload conditions based on the current reading; Displacement sensor unit, used to measure the position and displacement of key components of the equipment; A humidity sensor unit for measuring the humidity of the device environment; A gas sensor unit to monitor the composition and concentration of the gas around the device; A speed sensor unit, used to measure the running speed of the equipment; The sound sensor unit is used to monitor the operating sound of the device and determine whether the device has abnormal noise through sound wave analysis.

[0007] As a preferred technical solution of the present invention, the data transmission module includes: The wireless communication unit uses Zigbee module, which is used for long-distance and large-quantity sensor networks; Data relay unit, used to enhance signal strength and extend communication range; A data encryption unit, used for encrypting transmitted data; Data buffer unit, used to temporarily store data to be transmitted or received, smoothing sudden changes during data transmission; The data check unit is used to detect and correct errors during data transmission. As a preferred technical solution of the present invention, the data processing module includes: A data receiving unit, used for receiving data from the data transmission module; A data storage unit, used for persistently storing the collected historical data and processing results; A data cleaning unit is used to remove invalid or noisy data and detect and correct erroneous data that may occur during the transmission process; A data conversion unit, used to convert multiple data formats from different sources into a unified format; Data analysis unit, used to quickly analyze real-time data, extract key indicators and characteristic values, and perform statistical analysis on historical data to discover long-term trends and patterns; System management unit, used for system configuration and parameter adjustment.

[0008] As a preferred technical solution of the present invention, the risk assessment module includes: Risk identification unit, used to identify sources that may cause system failure or danger; The risk quantification unit uses statistical methods to analyze historical data and quantify the frequency and severity of various risks; The risk assessment unit evaluates and classifies the level of risk through the probability-impact matrix; Risk control unit, used to propose and implement risk mitigation measures and develop emergency response plans; Feedback unit, used to collect feedback after the implementation of risk control measures, evaluate the effects and make improvements.

[0009] As a preferred technical solution of the present invention, the early warning output module includes: Early warning notification unit provides a standardized API interface for data interaction with the MES system; An alarm unit that emits an audible alarm through a buzzer or speaker, or displays warning information in different colors or texts through an LED light or display screen; The warning display unit is used to display the warning information on the monitoring screen in the control room in the form of charts and curves, and intuitively display the system status; The warning storage unit is used to record all warning information, including time, type and processing results; User management unit, used to set the operation permissions of different users to ensure that only authorized personnel can receive and process warning information; The early warning test unit is used to support simulated early warning scenarios and test the effectiveness and response speed of the early warning system.

[0010] As a preferred technical solution of the present invention, the early warning notification unit adopts an API interface module to provide a standardized API interface to perform data interaction with the MES system.

[0011] As a preferred technical solution of the present invention, the visualization module includes: Overview panel unit, used to display the global status of the system; A chart display unit is used to display the change of parameters over time; Device status unit, used to display the status of different devices using standard icons or custom icons; The report generation unit is used to generate regular reports and analysis reports according to user needs, including data export function.

[0012] A risk early warning method for industrial control equipment comprises the following steps: S1: Collect the operation data of industrial control equipment through the data acquisition module; S2: Transmitting the operating data to the data processing module through the data transmission module; S3: After receiving the data, the data processing module performs preliminary processing and analysis and generates an analysis report; S4: Based on the analysis report generated by the data processing module, the risk assessment module performs risk assessment to determine whether there is potential risk; S5: If there is a potential risk, the warning output module issues a warning message; S6: Display the real-time operation status and warning information on the visual interface, and the operator performs corresponding operations based on the warning information.

[0013] Compared with the prior art, the present invention has at least the following beneficial technical effects: The risk early warning system and early warning method of industrial control equipment provided by the present invention collect the operating data of the industrial control equipment through a data acquisition module; perform preliminary processing and analysis through a data processing module to generate an analysis report; the risk assessment module performs risk assessment based on the analysis report generated by the data processing module to determine whether there is a potential risk; if there is a potential risk, the early warning output module issues an early warning message; therefore, real-time monitoring of the industrial control equipment is achieved, and potential risks can be discovered in time. The integrated design of the data processing module and the risk assessment module improves the processing speed and early warning accuracy of the system; by setting a visual interface, an intuitive display of the equipment status can be provided, which is convenient for operators to monitor and operate, thereby improving the safety and stability of the industrial control equipment and reducing the losses caused by equipment failures. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 is a system block diagram of the present invention; Figure 2 This is a block diagram of the data acquisition module of the present invention; Figure 3 This is a block diagram of the data transmission module of the present invention; Figure 4 This is a block diagram of the data processing module of the present invention; Figure 5 This is a block diagram of the risk assessment module of the present invention; Figure 6 This is a block diagram of the warning output module of the present invention Figure 7 This is a block diagram of the visualization module of the present invention; Figure 8 The figure is a flow chart of the method of the present invention. DETAILED DESCRIPTION

[0015] In the following, only some exemplary embodiments are briefly described. As those skilled in the art will appreciate, the described embodiments may be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and descriptions are considered to be exemplary and non-restrictive in nature.

[0016] It should be understood that when used in this specification and the appended claims, the terms "include" and "comprises" indicate the presence of described features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations thereof.

[0017] It should also be understood that the terms used in the present specification are only for the purpose of describing specific embodiments and are not intended to limit the present invention. As used in the present specification and the appended claims, unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" are intended to include plural forms.

[0018] It should be further understood that the term "and / or" used in the present description and the appended claims refers to any and all possible combinations of one or more of the associated listed items, and includes these combinations.

[0019] Various structural schematic diagrams of the embodiments disclosed in the present invention are shown in the accompanying drawings. These figures are not drawn to scale, and some details are magnified and some details may be omitted for the purpose of clear expression. The shapes of various regions and layers shown in the figures and the relative sizes and positional relationships therebetween are only exemplary, and may deviate in practice due to manufacturing tolerances or technical limitations, and those skilled in the art may additionally design regions / layers with different shapes, sizes, and relative positions according to actual needs.

[0020] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0021] Example 1 like Figure 1-7 As shown, this embodiment provides a risk warning system for industrial control equipment, including: Data acquisition module, used to collect operating data of industrial control equipment; The data acquisition module includes: Temperature sensor units are used to measure temperature changes at key locations in industrial control equipment, which can help identify possible faults caused by overheating; Pressure sensor unit, used to measure the pressure inside or outside the equipment to prevent mechanical failure or safety accidents caused by abnormal pressure; Current sensor unit, used to measure the current consumption of the equipment. The current reading can be used to determine whether the equipment has an electrical fault or overload condition; Displacement sensor unit, used to measure the position and displacement of key components of the equipment to ensure that it runs on the right track; Humidity sensor unit, used to measure the humidity of the equipment environment. Too high or too low humidity may affect the normal operation of the equipment. Gas sensor units, which monitor the composition and concentration of gases around the equipment, such as detecting toxic gas leaks; Speed ​​sensor unit, used to measure the running speed of the equipment. Abnormal speed may indicate efficiency problems or mechanical failure of the equipment. The sound sensor unit is used to monitor the operating sound of the equipment and determine whether the equipment has abnormal noise through sound wave analysis. Specifically, the above-mentioned various sensors are installed on equipment and key nodes. The sensors collect physical quantity data in real time and convert analog signals into digital signals through A / D converters. Noise and invalid data are preliminarily filtered out, and only valid data is retained. The collected data is cached in edge devices or local storage devices, ready to be transmitted to the central processing system.

[0022] A data transmission module, used to transmit the data obtained by the acquisition module to the data processing module; The data transmission module includes: The wireless communication unit uses Zigbee module, which is used for long-distance and large-quantity sensor networks; Data relay unit, used to enhance signal strength and extend communication range; A data encryption unit, used for encrypting transmitted data; Data buffer unit, used to temporarily store data to be transmitted or received, smoothing sudden changes during data transmission; A data check unit, used for error detection and correction during data transmission; Specifically, according to the system requirements and network environment, a suitable transmission protocol is selected, and Modbus is used to package the cached data into fixed-format data packets, attach metadata such as timestamps and device IDs, and transmit the data packets to the central processing system through a wireless network. Modbus is a universal language used in electronic controllers. Through this protocol, controllers can communicate with each other and with other devices via a network (such as Ethernet).

[0023] A data processing module, used to store and analyze the transmitted operation data; The data processing module includes: A data receiving unit, used for receiving data from the data transmission module; A data storage unit, used for persistently storing the collected historical data and processing results; A data cleaning unit is used to remove invalid or noisy data and detect and correct erroneous data that may occur during the transmission process; A data conversion unit, used to convert multiple data formats from different sources into a unified format; Data analysis unit, used to quickly analyze real-time data, extract key indicators and characteristic values, and perform statistical analysis on historical data to discover long-term trends and patterns; System management unit, used for system configuration and parameter adjustment; Specifically, the received data packets are unpacked and valid data is stored in a database, such as a NoSQL database. The data is further cleaned to remove outliers and null values ​​to ensure data quality. The data is summarized, grouped, and aggregated to generate summary indicators at each level. Key feature information is extracted as needed, such as mean, maximum, minimum, standard deviation, etc., to provide a basis for risk assessment.

[0024] The risk assessment module is used to conduct risk assessment based on the analysis results of the data processing module to determine whether there are potential risks; The risk assessment modules include: Risk identification unit, used to identify sources that may cause system failure or danger; The risk quantification unit uses statistical methods to analyze historical data and quantify the frequency and severity of various risks; The risk assessment unit evaluates and classifies the level of risk through the probability-impact matrix; Risk control unit, used to propose and implement risk mitigation measures and develop emergency response plans; Feedback unit, which is used to collect feedback after implementing risk control measures, evaluate the effects and make improvements; Specifically, based on predefined risk assessment rules, real-time data is initially evaluated using threshold rules, and advanced algorithms such as machine learning and artificial intelligence are applied to conduct in-depth data analysis and risk prediction. The results of the comprehensive analysis are used to calculate specific risk scores or risk levels, classify different types of risks, and archive them to form a risk classification report.

[0025] The early warning output module is used to send early warning information to operators and management systems when potential risks are detected; The warning output module includes: The early warning notification unit adopts the API interface module and provides a standardized API interface for data interaction with the MES system. The API interface defines standard specifications to achieve communication and data transmission between different software systems, thereby enhancing the interoperability and scalability of the system.

[0026] An alarm unit that emits an audible alarm through a buzzer or speaker, or displays warning information in different colors or texts through an LED light or display screen; The warning display unit is used to display the warning information on the monitoring screen in the control room through charts, curves, etc., and intuitively display the system status; The warning storage unit is used to record all warning information, including time, type, processing results, etc.; User management unit, used to set the operation permissions of different users to ensure that only authorized personnel can receive and process warning information; Early warning test unit, used to support simulated early warning scenarios and test the effectiveness and response speed of the early warning system; Specifically, early warning strategies are configured according to different risk levels and categories, including notification methods, processing procedures, etc. When one or more risk assessment results exceed the predetermined threshold, the early warning mechanism is triggered, and the early warning information is conveyed to relevant personnel or systems through SMS, email, push notification, sound and light alarms, etc. According to the early warning strategy, emergency response measures are automatically triggered, such as automatic shutdown, valve closure, etc.

[0027] Visualization module, used to display the real-time operation status and warning information of the equipment; The visualization modules include: Overview panel unit, used to display the global status of the system; A chart display unit is used to display the change of parameters over time; Device status unit, used to display the status of different devices using standard icons or custom icons; Report generation unit, used to generate regular reports and analysis reports according to user needs, including data export function; Specifically, design the user interface layout, including real-time monitoring panel, chart display module, 3D visualization, etc., bind the data generated by the processing module with the various display components on the interface, realize real-time data update, and provide user interface interactive functions, such as data filtering, historical data query, alarm confirmation, parameter adjustment, etc., through dynamic graphics, animation, etc., intuitively display the system operation status, parameter changes, risk warnings and other contents, ensure the compatibility of the interface on different devices and platforms, such as PC, tablets, and mobile phones, to provide a consistent user experience.

[0028] Example 2 like Figure 8 As shown, this embodiment provides a risk warning method for industrial control equipment, comprising the following steps: S1: Collect the operation data of industrial control equipment through the data acquisition module; S2: Transmitting the operating data to the data processing module through the data transmission module; S3: After receiving the data, the data processing module performs preliminary processing and analysis and generates an analysis report; S4: Based on the report generated by the data processing module, the risk assessment module performs risk assessment to determine whether there is potential risk; S5: If there is a potential risk, the warning output module issues a warning message; S6: Display the real-time operation status and warning information on the visual interface, and the operator performs corresponding operations based on the warning information.

[0029] Example 3 This embodiment provides an API interface module, a standardized API interface to interact with the MES system for data; the API interface defines standard specifications to achieve communication and data transmission between different software systems, thereby enhancing the interoperability and scalability of the system; The API interface module usually involves standardized definitions of data formats, transmission protocols, request methods, and response formats. It is a bridge connecting different software components, allowing developers to call other services or functions in their own applications, thereby achieving function reuse and system interconnection; Therefore, in the process of designing and implementing the API interface, this application will take into account multiple factors such as functionality, security, performance and maintainability to ensure that the API interface is efficient, secure and easy to use.

[0030] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It is obvious to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention. Therefore, no matter from which point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the attached claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims are included in the present invention. Any figure mark in the claims should not be regarded as limiting the claims involved.

[0031] In addition, it should be understood that although this specification is described in accordance with the implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation modes that can be understood by those skilled in the art. The above content is only to illustrate the technical idea of ​​the present invention, and cannot be used to limit the protection scope of the present invention. Any changes made on the basis of the technical solution according to the technical idea proposed by the present invention shall fall within the protection scope of the claims of the present invention.

Claims

1. A risk early warning system for industrial control equipment, characterized in that: include: Data acquisition module, used to collect operating data of industrial control equipment; A data transmission module, used for transmitting the operation data collected by the data collection module to the data processing module; A data processing module, used to store and analyze the transmitted operation data; The risk assessment module is used to conduct risk assessment based on the analysis results of the data processing module to determine whether there are potential risks; The early warning output module is used to send early warning information to operators and management systems when potential risks are detected; Visualization module, used to display the real-time operation status and warning information of the equipment.

2. The risk early warning system for industrial control equipment according to claim 1 is characterized in that: The data acquisition module includes: Temperature sensor unit, used to measure temperature changes in key parts of industrial control equipment; Pressure sensor unit, used to measure pressure conditions inside or outside the equipment; Current sensor unit, used to measure the current consumption of the equipment, and determine whether the equipment has electrical faults or overload conditions based on the current reading; Displacement sensor unit, used to measure the position and displacement of key components of the equipment; A humidity sensor unit for measuring the humidity of the device environment; A gas sensor unit to monitor the composition and concentration of the gas around the device; A speed sensor unit, used to measure the running speed of the equipment; The sound sensor unit is used to monitor the operating sound of the device and determine whether the device has abnormal noise through sound wave analysis.

3. The risk early warning system for industrial control equipment according to claim 1 is characterized in that: The data transmission module includes: The wireless communication unit uses Zigbee module, which is used for long-distance and large-quantity sensor networks; Data relay unit, used to enhance signal strength and extend communication range; A data encryption unit, used for encrypting transmitted data; Data buffer unit, used to temporarily store data to be transmitted or received, smoothing sudden changes during data transmission; The data check unit is used to detect and correct errors during data transmission.

4. The risk early warning system for industrial control equipment according to claim 1 is characterized in that: The data processing module includes: A data receiving unit, used for receiving data from the data transmission module; A data storage unit, used for persistently storing the collected historical data and processing results; A data cleaning unit is used to remove invalid or noisy data and detect and correct erroneous data that may occur during the transmission process; A data conversion unit, used to convert multiple data formats from different sources into a unified format; Data analysis unit, used to quickly analyze real-time data, extract key indicators and characteristic values, and perform statistical analysis on historical data to discover long-term trends and patterns; System management unit, used for system configuration and parameter adjustment.

5. The risk early warning system for industrial control equipment according to claim 1 is characterized in that: The risk assessment modules include: Risk identification unit, used to identify sources that may cause system failure or danger; Risk quantification unit, which analyzes historical data and quantifies the frequency and severity of various risks; The risk assessment unit evaluates and classifies the level of risk through the probability-impact matrix; Risk control unit, used to propose and implement risk mitigation measures and develop emergency response plans; Feedback unit, used to collect feedback after the implementation of risk control measures, evaluate the effects and make improvements.

6. A risk early warning system for industrial control equipment according to claim 5, characterized in that: The Risk Quantification Unit uses statistical methods to analyze historical data.

7. The risk early warning system for industrial control equipment according to claim 1 is characterized in that: The warning output module includes: Early warning notification unit provides a standardized API interface for data interaction with the MES system; An alarm unit that emits an audible alarm through a buzzer or speaker, or displays warning information in different colors or texts through an LED light or display screen; The warning display unit is used to display the warning information on the monitoring screen in the control room in the form of charts and curves, and intuitively display the system status; The warning storage unit is used to record all warning information, including time, type and processing results; User management unit, used to set the operation permissions of different users to ensure that only authorized personnel can receive and process warning information; The early warning test unit is used to support simulated early warning scenarios and test the effectiveness and response speed of the early warning system.

8. The risk early warning system for industrial control equipment according to claim 7, characterized in that: The early warning notification unit uses an API interface module to provide a standardized API interface for data interaction with the MES system.

9. The risk early warning system for industrial control equipment according to claim 1, characterized in that: The visualization modules include: Overview panel unit, used to display the global status of the system; A chart display unit is used to display the change of parameters over time; Device status unit, used to display the status of different devices using standard icons or custom icons; The report generation unit is used to generate regular reports and analysis reports according to user needs, including data export function.

10. A risk early warning method for industrial control equipment, characterized in that: include: Collect the operation data of industrial control equipment through the data acquisition module; The operating data is transmitted to the data processing module through the data transmission module; After receiving the data, the data processing module performs preliminary processing and analysis and generates an analysis report; Based on the analysis report generated by the data processing module, the risk assessment module conducts risk assessment to determine whether there are potential risks; If there is a potential risk, the early warning output module will issue an early warning message; The real-time operating status and warning information are displayed on the visual interface, and the operator performs corresponding operations based on the warning information.

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