Industrial control equipment data acquisition system and acquisition method

Abstract

The invention discloses an industrial control equipment data acquisition system and method, and the system comprises a sensor module which is installed on industrial control equipment and is used for detecting various parameters of the control equipment; the data acquisition module is connected with the sensor module and is used for acquiring an output signal of the sensor in real time; the data processing module is used for preprocessing the collected data, improving the data quality and reducing the storage space; the communication module is used for transmitting the processed data to a remote monitoring system and supports wired and wireless communication modes; the control module is used for comprehensively processing and analyzing data and providing decision support for industrial control; according to the data acquisition system and the data acquisition method, the operation data of the industrial control equipment can be efficiently and accurately acquired, the real-time performance and the precision are remarkably improved, the data quality is effectively improved through the optimal design of the data processing module, noise and redundant data are reduced, and meanwhile, storage and transmission loads are reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of industrial data, and specifically relates to an industrial control equipment data acquisition system and acquisition method. Background Art

[0002] With the evolution of large-scale industrial production, the importance of monitoring technology on production equipment has gradually been recognized by people. Whether it is production management, parts management, equipment management, order management, or corporate decision-making, it is inseparable from the timely grasp of on-site production conditions. With the increasing degree of integration of industrialization and informatization, the large-scale development of industrial data collection, industrial data security is particularly important, especially for the collection of industrial process data related to on-site equipment control. In these data collection processes, the existing collection method is generally to directly connect to the equipment controller through the server, directly access the controller through software, and pass real-time data from the controller. With the continuous deepening of industrial intelligent control, it is not just data collection. There are more and more cases where intelligent control systems control industrial equipment through controllers. This also means that there will be opportunities to change the control signals in the controller; In modern industrial production, data acquisition systems are the core components for process monitoring and optimization. Traditional data acquisition systems have deficiencies in real-time, reliability, and intelligent data processing, and are unable to meet the needs of complex production environments and high-precision control. Summary of the invention

[0003] The purpose of the present invention is to provide an industrial control equipment data acquisition system and acquisition method, which solves the problems in the background technology.

[0004] In order to achieve the above object, the present invention adopts the following technical solution: The present invention provides an industrial control equipment data acquisition system, comprising: Sensor modules are installed on industrial control equipment to detect various parameters of the control equipment; A data acquisition module is connected to the sensor module and is used to collect the output signal of the sensor in real time; The data processing module is used to pre-process the data collected by the data collection module to improve data quality and reduce storage space; The communication module is used to transmit the data processed by the data processing module to the remote monitoring system, supporting wired and wireless communication modes; The control module is connected with the data acquisition module and is used to comprehensively process and analyze data to provide decision support for industrial control.

[0005] A further improvement of the present invention is that the data acquisition module comprises: A signal conditioning unit, used for conditioning the original output signal of the sensor; The data acquisition control unit is used to control and manage the entire data acquisition process, coordinate the work of each unit in the data acquisition module, and communicate with the signal conditioning unit; A buffer storage unit for temporarily storing the collected data; Power management unit, used to provide stable power supply; The calibration unit is used to automatically calibrate the sensor and acquisition system at regular intervals.

[0006] A further improvement of the present invention is that the data processing module comprises: A data filtering unit, used for preprocessing the collected data; A data compression unit for improving the quality of collected data; The data storage unit is used to reduce the storage space of the collected data.

[0007] A further improvement of the present invention is that the data filtering unit adopts a Kalman filtering algorithm.

[0008] A further improvement of the present invention is that the control module comprises: The central processing unit is responsible for executing the core computing and processing tasks of the control module; Alarm processing unit, used to detect abnormal conditions in the operation of industrial control systems; A control algorithm unit, used to implement a specific control algorithm for industrial control equipment; Remote management unit, used to support remote system monitoring and maintenance, and realize remote operation through the Internet or dedicated network.

[0009] A further improvement of the present invention is that the sensor module includes a temperature sensor, a pressure sensor, a flow sensor, a current sensor and a voltage sensor.

[0010] The present invention also provides an industrial control equipment data acquisition method, comprising: Obtain various operating parameters of industrial control equipment in real time through sensor modules; Transmit the output signal of the sensor module to the data acquisition module for real-time data acquisition; The collected data is preprocessed in the data processing module by filtering, compressing and storing; The processed data is transmitted to the remote monitoring system using the communication module; The collected data is comprehensively processed and analyzed in the control module to provide decision support for industrial control.

[0011] A further improvement of the present invention is that the data acquisition module conditions the original output signal of the sensor through the signal conditioning unit; controls and manages the entire data acquisition process through the data acquisition control unit, coordinates the work of each unit in the data acquisition module, and communicates with the signal conditioning unit; temporarily stores the collected data through the buffer storage unit; provides a stable power supply through the power management unit; and automatically calibrates the sensor and the acquisition system regularly through the calibration unit.

[0012] A further improvement of the present invention is that the data processing module pre-processes the collected data through a data filtering unit; improves the quality of the collected data through a data compression unit; and reduces the storage space of the collected data through a data storage unit.

[0013] A further improvement of the present invention is that the control module is responsible for executing the core calculation and processing tasks of the control module through the central processing unit; abnormal conditions in the operation of the industrial control system are detected through the alarm processing unit; specific control algorithms for industrial control equipment are implemented through the control algorithm unit; remote system monitoring and maintenance are supported through the remote management unit, and remote operation is achieved through the Internet or a dedicated network.

[0014] Compared with the prior art, the present invention has at least the following beneficial technical effects: The present invention provides an industrial control equipment data acquisition system and method, which can efficiently and accurately collect the operating data of the industrial control equipment by setting a sensor module, a data acquisition module and a control module, and the real-time performance and accuracy are significantly improved. The optimized design of the data processing module effectively improves the data quality, reduces noise and redundant data, and reduces the storage and transmission load.

[0015] The present invention provides an industrial control equipment data acquisition system and acquisition method. By setting a communication module that can support multiple communication modes, the flexibility and adaptability of the system are improved, and the needs of different industrial environments can be met. The control unit improves the automation level and decision-making ability of the industrial control system by intelligently analyzing and processing data. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a structural block diagram of an industrial control equipment data acquisition system of the present invention; Figure 2 The present invention is a flow chart of a method for collecting data of industrial control equipment. DETAILED DESCRIPTION

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0023] Example 1 like Figure 1 As shown, this embodiment provides an industrial control equipment data acquisition system, including: Sensor modules are installed on industrial control equipment to detect various parameters of the control equipment; The sensor module includes a temperature sensor, a pressure sensor, a flow sensor, a current sensor and a voltage sensor.

[0024] A data acquisition module is connected to the sensor module and is used to collect the output signal of the sensor in real time; The data acquisition module includes: The signal conditioning unit is used to condition the original output signal of the sensor. Specifically, it includes processes such as amplification, filtering and calibration to ensure that the signal maintains high quality and stability in subsequent processing units; Data acquisition control unit, used to control and manage the entire data acquisition process, coordinate the work of each unit, and communicate with the signal conditioning unit; Specifically, it includes a microprocessor or microcontroller for performing control logic and simple data processing tasks during acquisition and transmission; Buffer storage unit, used to temporarily store collected data to cope with delays and fluctuations in data transmission and ensure that data is not lost; Specifically, a FIFO queue structure is used. A FIFO (First In First Out) queue is a linear data structure that follows the first-in, first-out principle, that is, the element that first enters the queue will be removed from the queue first. The queue only allows elements to be added at the rear and removed at the front.

[0025] The power management unit is used to provide a stable power supply to ensure the normal operation of each component of the data acquisition module; Specifically, it includes power regulation, voltage conversion and power monitoring functions The calibration unit is used to automatically calibrate the sensor and acquisition system regularly to ensure the acquisition accuracy and reliability in long-term use.

[0026] The data processing module is connected to the data acquisition module and is used to pre-process the collected data to improve data quality and reduce storage space; The data processing module includes: A data filtering unit, used for preprocessing the collected data; The data filtering unit uses the Kalman filter algorithm; the Kalman filter algorithm is a linear minimum variance estimator, which is mainly used to estimate the state of a random process or system in the presence of noise. The Kalman filter algorithm continuously optimizes the estimation of the system state through a series of iterative steps. The core idea of ​​the algorithm is to use the state equation and observation equation of the linear dynamic system to gradually approach the true state through two main steps: prediction and update.

[0027] A data compression unit for improving the quality of collected data; The data storage unit is used to reduce the storage space of the collected data.

[0028] The communication module is used to transmit the processed data to the remote monitoring system and supports wired and wireless communication.

[0029] Control module, used for comprehensive processing and analysis of data to provide decision support for industrial control; The control module includes: The central processing unit is responsible for executing the core computing and processing tasks of the control module; Specifically, high-performance microprocessors are selected to meet complex data processing and real-time control requirements; for example, the IBM Power8 processor is a high-performance processor designed for the enterprise market. It provides a large number of cores and high-speed caches to support large databases and complex enterprise applications. Alarm processing unit, used to detect abnormal conditions in the operation of industrial control systems, including anomaly detection algorithms, alarm level settings and alarm outputs; The control algorithm unit is used to implement specific control algorithms for industrial control equipment, including PID control, fuzzy control and adaptive control; PID control, the full name of which is proportional-integral-derivative control, is a classic and widely used control method. It controls the controlled object by linearly combining the proportion (P), integral (I) and differential (D) of the deviation to form the control quantity. Fuzzy control is a computer digital control technology based on fuzzy set theory, fuzzy language variables and fuzzy logic reasoning. It uses the basic ideas and theories of fuzzy mathematics to deal with control problems that are difficult to describe with precise mathematical models. Adaptive control is a control method that can modify its own characteristics to adapt to the dynamic characteristics of the object and disturbance. It faces a system with a certain degree of uncertainty, which may come from disturbances inside the system or the external environment.

[0030] Specifically, according to the output results of the data analysis unit, the corresponding control tasks are executed Remote management unit, used to support remote system monitoring and maintenance, remote operation through the Internet or dedicated network; monitoring and management of production equipment distributed in different geographical locations, real-time collection and transmission of equipment data, remote fault diagnosis and maintenance, and firmware updates; Specifically, it includes installing the remote management unit on the target device or environment and ensuring its stable network connection; performing initial configuration of the device through the local interface (such as USB, serial port) or network interface, including network parameters, device ID, management platform address, etc.; Network connection: wired connection, directly connected to the local network or the Internet through an Ethernet interface, wireless connection: connected to the network through Wi-Fi, cellular network or other wireless communication means; Remote monitoring and management: Equipment monitoring, monitoring the operating status, environmental parameters and fault conditions of the equipment through the built-in sensors and interfaces of the remote management unit; data collection and transmission, real-time or periodic collection of equipment data, and transmission to the remote management platform through the network; fault diagnosis, fault diagnosis through log files and real-time data analysis, and providing alarm function.

[0031] Remote configuration and control: parameter configuration, modify and update device configuration parameters such as operating mode, alarm threshold, etc. through the remote management platform; remote execution command: send control commands to start, stop, restart and other operations of the device.

[0032] Firmware update: Download and verify, download the new firmware update package from the remote management platform and perform integrity verification; firmware upgrade, perform firmware upgrade operations through the remote management unit to ensure the security and functionality of device operation.

[0033] Security management: Identity authentication, authenticating users and systems accessing the remote management unit; access control, configuring access rights to ensure that only authorized users can perform management operations.

[0034] Example 2 like Figure 1 As shown, this embodiment provides an industrial control equipment data collection method, comprising the following steps: S1: Data acquisition, real-time acquisition of various operating parameters of industrial control equipment through sensor modules; S2: Data acquisition, transmitting the output signal of the sensor module to the data acquisition module for real-time data acquisition; S3: Data processing, in which the collected data is preprocessed through filtering, compression and storage steps; S4: Data transmission, using the communication module to transmit the processed data to the remote monitoring system; S5: Data analysis, comprehensive processing and analysis of collected data in the control module to provide decision support for industrial control.

[0035] Example 3 In an industrial manufacturing process provided by this embodiment, the temperature, pressure, flow, current and voltage of machine equipment are collected through sensors; then the data of each sensor is collected through the collection module, and the collected data is transmitted to the data processing module for processing, such as filtering out noise data and compressing and storing data; the processed data is transmitted to the cloud platform through the 5G communication module for further analysis and storage; the user views real-time data through the touch screen interface and can adjust the temperature warning threshold; when the system detects that the temperature, pressure, flow, current or voltage exceeds the set threshold, it automatically triggers the corresponding processing equipment to run through the PLC and sends an alarm notification to the user.

[0036] Example 4 A remote management platform provided in this embodiment adopts ManageEngine Desktop Central; Implementation method: Resource acquisition and distribution: manage software, patches, applications, and distribute them to different system groups; Device management: remote power on / off, reboot, logout, as well as system monitoring and resource auditing; Security controls: Implement high-priority security updates, collect and track various performance parameters; Application and system configuration management: Simplify customization and implement unified configuration strategies.

[0037] Example 5 This embodiment provides a computer-readable storage medium, which stores a computer program. When the computer program is executed by a processor, the steps of the industrial control equipment data collection method are implemented.

[0038] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present application may adopt the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program codes.

[0039] The present application is described with reference to the flowcharts and / or block diagrams of the methods, systems and computer program products according to the embodiments of the present application. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of the processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A system that specifies the functions of a box or multiple boxes.

[0040] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0041] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0042] 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.

[0043] 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. An industrial control equipment data acquisition system, characterized in that: include: Sensor modules are installed on industrial control equipment to detect various parameters of the control equipment; A data acquisition module is connected to the sensor module and is used to collect the output signal of the sensor in real time; The data processing module is used to pre-process the data collected by the data collection module to improve data quality and reduce storage space; The communication module is used to transmit the data processed by the data processing module to the remote monitoring system, supporting wired and wireless communication modes; The control module is connected with the data acquisition module and is used to comprehensively process and analyze data to provide decision support for industrial control.

2. The industrial control equipment data acquisition system according to claim 1, characterized in that: The data acquisition module includes: A signal conditioning unit, used for conditioning the original output signal of the sensor; The data acquisition control unit is used to control and manage the entire data acquisition process, coordinate the work of each unit in the data acquisition module, and communicate with the signal conditioning unit; A buffer storage unit for temporarily storing the collected data; Power management unit, used to provide stable power supply; The calibration unit is used to automatically calibrate the sensor and acquisition system at regular intervals.

3. The industrial control equipment data acquisition system according to claim 1, characterized in that: The data processing module includes: A data filtering unit, used for preprocessing the collected data; A data compression unit for improving the quality of collected data; The data storage unit is used to reduce the storage space of the collected data.

4. The industrial control equipment data acquisition system according to claim 3, characterized in that: The data filtering unit adopts the Kalman filtering algorithm.

5. The industrial control equipment data acquisition system according to claim 1, characterized in that: The control module includes: The central processing unit is responsible for executing the core computing and processing tasks of the control module; Alarm processing unit, used to detect abnormal conditions in the operation of industrial control systems; A control algorithm unit, used to implement a specific control algorithm for industrial control equipment; Remote management unit, used to support remote system monitoring and maintenance, and realize remote operation through the Internet or dedicated network.

6. The industrial control equipment data acquisition system according to claim 1, characterized in that: The sensor module includes a temperature sensor, a pressure sensor, a flow sensor, a current sensor and a voltage sensor.

7. A method for collecting data from industrial control equipment, characterized in that: include: Obtain various operating parameters of industrial control equipment in real time through sensor modules; Transmit the output signal of the sensor module to the data acquisition module for real-time data acquisition; The collected data is preprocessed in the data processing module by filtering, compressing and storing; The processed data is transmitted to the remote monitoring system using the communication module; The collected data is comprehensively processed and analyzed in the control module to provide decision support for industrial control.

8. The method for collecting data of industrial control equipment according to claim 7, characterized in that: The data acquisition module conditions the original output signal of the sensor through the signal conditioning unit; controls and manages the entire data acquisition process through the data acquisition control unit, coordinates the work of each unit in the data acquisition module, and communicates with the signal conditioning unit; temporarily stores the collected data through the buffer storage unit; provides a stable power supply through the power management unit; and automatically calibrates the sensor and acquisition system regularly through the calibration unit.

9. The method for collecting data of industrial control equipment according to claim 7, characterized in that: The data processing module pre-processes the collected data through the data filtering unit; improves the quality of the collected data through the data compression unit; and reduces the storage space of the collected data through the data storage unit.

10. The industrial control equipment data collection method according to claim 7, characterized in that: The control module is responsible for executing the core calculation and processing tasks of the control module through the central processing unit; detecting abnormal conditions in the operation of the industrial control system through the alarm processing unit; implementing specific control algorithms for industrial control equipment through the control algorithm unit; supporting remote system monitoring and maintenance through the remote management unit, and realizing remote operation through the Internet or a dedicated network.

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