Automatic equipment data collection and analysis system based on Internet

Abstract

The invention relates to the technical field of automation equipment anomaly detection, and discloses an Internet-based automation equipment data collection and analysis system. According to the system, various sensors are used for collecting various key data of equipment operation in real time, the key data are efficiently transmitted to the data storage module through an MQTT protocol, the data analysis module carries out deep analysis on the collected data, the average value and the health index of equipment operation are calculated, scientific evaluation is provided for the equipment state, and the safety of equipment operation is improved. The monitoring alarm module performs intelligent judgment according to a set health threshold value and sends an early warning signal to a user in time and provides a solution once an abnormality is found, so that the response speed and the processing efficiency of equipment faults are remarkably improved, and the user interface module displays real-time data and analysis results through a friendly operation interface; the user can visually know the operation condition of the equipment, and the implementation of the system not only improves the intelligent level of equipment management and reduces the failure rate, but also provides more efficient operation experience for the user.

Description

Technical Field

[0001] The present invention relates to the technical field of abnormality detection of automated equipment, and in particular to an automated equipment data collection and analysis system based on the Internet. Background Art

[0002] In the field of modern industry and automation, with the continuous advancement of science and technology, automation equipment is playing an increasingly important role in production, monitoring and data analysis. Through in-depth analysis of the collected data, enterprises can obtain the operating status, performance indicators and potential fault warnings of the equipment, thereby realizing equipment status monitoring and maintenance.

[0003] Many traditional systems rely on a single or limited type of sensor, which makes it difficult to fully capture the multi-dimensional data of equipment operation. This limitation results in the system often only being able to provide superficial information when evaluating equipment status, lacking sufficient accuracy and reliability. Summary of the invention

[0004] 1. Technical issues to be resolved

[0005] In view of the shortcomings of the prior art, the present invention provides an Internet-based automated equipment data collection and analysis system, which is capable of collecting various key data of equipment operation in real time by utilizing a variety of sensors, and efficiently transmitting them to the data storage module through the MQTT protocol, thereby ensuring the timeliness and integrity of the data. The data analysis module conducts in-depth analysis of the collected data, not only calculating the mean of equipment operation, but also generating a health index to provide a scientific assessment of the equipment status. The monitoring and alarm module makes intelligent judgments based on set health thresholds. Once an abnormality is found, it promptly sends an early warning signal to the user and provides a solution, thereby significantly improving the response speed and processing efficiency of equipment failures. In addition, the user interface module displays real-time data and analysis results in a friendly operation interface, allowing users to intuitively understand the operation of the equipment. The implementation of this system not only improves the level of intelligence of equipment management and reduces the failure rate, but also provides users with a more efficient operation experience and other advantages, thereby solving the above-mentioned problems.

[0006] (II) Technical solution

[0007] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: an Internet-based automated equipment data collection and analysis system, comprising an equipment data acquisition module, an equipment data storage module, an equipment data analysis module, a monitoring and alarm module, and a user interface module;

[0008] The equipment data acquisition module collects the operating temperature, operating pressure, operating environment humidity, operating voltage, operating speed, operating current and operating status data of the automation equipment through the temperature sensor, humidity sensor, pressure sensor, speed sensor, voltage sensor, current sensor and automation equipment interface, and transmits them to the equipment data storage module through the MQTT Internet communication protocol;

[0009] The device data storage module uses a relational database to store the data transmitted by the device data acquisition module;

[0010] The equipment data analysis module retrieves the data in the equipment data storage module for analysis, calculates the average operating temperature of the automation equipment, the average operating pressure of the automation equipment, the average operating humidity of the automation equipment environment, the average operating speed of the automation equipment, the average operating current of the automation equipment, and the average operating voltage of the automation equipment, and calculates the health index of the automation equipment and sends it to the monitoring and alarm module;

[0011] The monitoring and alarm module has a built-in automation equipment health threshold, analyzes and compares the automation equipment health index with the automation equipment health threshold, determines the operating status of the automation equipment, and sends a warning signal to the user interface module when an abnormality occurs;

[0012] The user interface module provides an operation interface for the user, displays the data analysis results and monitoring status of the automation equipment, and displays solutions to abnormal operation of the automation equipment on the user operation interface according to the early warning signal.

[0013] Preferably, the calculation formula for the mean operating temperature of the automation equipment is as follows:

[0014]

[0015] In the formula, Indicates the average operating temperature of automation equipment. Represents the total number of measured temperature data points, Indicates The measured temperature data values, Indicates a counting subscript.

[0016] Preferably, the calculation formula for the mean operating pressure of the automation equipment is as follows:

[0017]

[0018] In the formula, Indicates the average operating pressure of automation equipment. Indicates the total number of measured pressure data points, Indicates The measured pressure data values, Indicates the sequence number of the pressure data point.

[0019] Preferably, the calculation formula for the mean humidity of the operating environment of the automation equipment is as follows:

[0020]

[0021] In the formula, Indicates the average humidity of the operating environment of the automation equipment. Represents the total number of humidity data points measured, The count subscript representing the ambient humidity, Indicates The measured ambient humidity data value.

[0022] Preferably, the calculation formula for the average speed of the automation equipment is as follows:

[0023]

[0024] In the formula, Indicates the average speed of the automation equipment. Indicates the total number of speed data points measured, represents a count subscript, Indicates The measured speed data value.

[0025] Preferably, the calculation formula for the mean operating current of the automation equipment is as follows:

[0026]

[0027] In the formula, Indicates the average operating current of the automation equipment. Represents the total number of measured current data points, Indicates The square of the measured current data value, A count subscript indicating the number of current data.

[0028] Preferably, the calculation formula for the mean operating voltage of the automation equipment is as follows:

[0029]

[0030] In the formula, Indicates the average operating voltage of automation equipment. Indicates the total number of measured voltage data points, Indicates The square of the measured voltage data value, A count subscript indicating the number of voltage data.

[0031] Preferably, the calculation formula of the automation equipment health index is as follows:

[0032]

[0033] In the formula, Represents the automation equipment health index, , , , , , Indicates the weight coefficient of the corresponding value.

[0034] Preferably, the calculation formula of the weight coefficient is as follows:

[0035]

[0036] In the formula, Indicates The weight coefficient of each indicator is It indicates the normalized operating temperature, operating pressure, operating environment humidity, operating voltage, operating speed and operating current of the automation equipment. Represents the sum of all normalized index values, subscript From 1 to 6, where 6 is the total number of indicators, this sum represents the combined impact of all indicators and provides a benchmark to measure the relative weight of each indicator.

[0037] Preferably, the operating status judgment conditions of the automation equipment are as follows:

[0038] When the automation equipment health index When the calculated result is greater than the health threshold of the automation equipment, the monitoring alarm module will issue a warning signal. As a sign of abnormality in automation equipment.

[0039] Compared with the prior art, the present invention provides an Internet-based automation equipment data collection and analysis system, which has the following beneficial effects:

[0040] The present invention utilizes a variety of sensors to collect various key data of equipment operation in real time, and efficiently transmits them to the data storage module through the MQTT protocol to ensure the timeliness and integrity of the data. The data analysis module conducts in-depth analysis of the collected data, not only calculating the mean value of equipment operation, but also generating a health index to provide a scientific assessment of the equipment status. The monitoring and alarm module makes intelligent judgments based on the set health thresholds. Once an abnormality is found, it promptly sends an early warning signal to the user and provides a solution, which significantly improves the response speed and processing efficiency of equipment failures. In addition, the user interface module displays real-time data and analysis results in a friendly operation interface, allowing users to intuitively understand the operation of the equipment. The implementation of this system not only improves the intelligence level of equipment management and reduces the failure rate, but also provides users with a more efficient operation experience. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 It is a schematic diagram of the system flow of the present invention. DETAILED DESCRIPTION

[0042] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0043] In view of the fact that traditional systems rely on a single or limited type of sensors and are unable to fully capture the multi-dimensional data of equipment operation, this limitation results in the system often only being able to provide superficial information when evaluating equipment status, lacking sufficient accuracy and reliability. Therefore, an Internet-based automated equipment data collection and analysis system is proposed. Figure 1 ,The system includes an equipment data acquisition module, an equipment data storage module, an equipment data analysis module, a monitoring and alarm module and a user interface module;

[0044] The equipment data acquisition module integrates multiple sensors to achieve accurate monitoring and data collection of the operating status of automation equipment. Specifically, the temperature sensor is used to transparently detect and record the operating temperature of the equipment to ensure that the temperature is maintained within a safe range to prevent the risk of overheating. The humidity sensor monitors the relative humidity of the environment to help manage climate conditions to optimize equipment performance. The pressure sensor collects equipment pressure information in real time to detect the working stability and safety of the system. At the same time, the monitoring of operating voltage and current relies on voltage and current sensors to ensure the reliability of the equipment power supply and prevent abnormal operation caused by power fluctuations. In addition, the speed sensor can provide real-time feedback on the operating frequency of the equipment to provide data support for the optimization of the power system.

[0045] In terms of setting the safety range of temperature, pressure, humidity, speed, current and voltage, the system comprehensively considers the factory indicators and actual operation history data of the equipment. The initial safety range is based on the technical specifications provided by the equipment manufacturer. These specifications are obtained through rigorous testing to ensure that the equipment operates safely under the designed working conditions. However, as the equipment is used, the system will continue to collect operation history data. By analyzing these data, the optimal operating state of the equipment under different working environments and conditions can be identified, so as to dynamically adjust the safety range. This hybrid method combining factory indicators and historical data not only improves the accuracy of the safety threshold, but also enhances the adaptability of the system, ensuring the stability and safety of the equipment in actual applications.

[0046] All these sensors process the collected data centrally through the automation device interface to generate real-time equipment operation status information. In order to achieve efficient and low-latency data transmission, the data acquisition module adopts the MQTT (Message Queue Telemetry Transport) Internet communication protocol, which is a lightweight message protocol that is particularly suitable for inter-device communication in the IoT environment. The publish / subscribe mode of the MQTT protocol supports efficient message transmission between devices and data storage modules, ensuring real-time data update and reception;

[0047] The equipment data storage module uses a relational database management system (RDBMS) to efficiently store and manage the multi-dimensional data transmitted from the equipment data acquisition module. The relational database organizes data in the form of tables, ensures the structuring of data through predefined schemas, and provides integrity constraints and data consistency. Each type of sensor data (such as temperature, humidity, pressure, voltage, current, and speed) is stored in a specific data table to facilitate subsequent data query and analysis;

[0048] In order to achieve efficient data operations, the data storage module inserts, updates, deletes and queries data through SQL (Structured Query Language) to ensure real-time and accuracy. The data storage module regularly receives MQTT messages from the device data acquisition module and uses data parsing algorithms to convert the received JSON format data into a usable structure in a relational database. By setting appropriate indexes, the database can quickly respond to query requests for device operating status, thereby providing real-time monitoring capabilities.

[0049] In addition, the transaction processing mechanism of relational databases ensures the atomicity, consistency, isolation and persistence (ACID characteristics) of data during writing, which greatly improves the reliability of data. In the context of large-scale data storage, in order to improve performance and scalability, the database module can also use technical means such as partitioning, replication and load balancing to meet the needs of data growth while ensuring the optimization of query and storage performance;

[0050] The equipment data analysis module retrieves the data in the equipment data storage module for analysis, calculates the average operating temperature of the automation equipment, the average operating pressure of the automation equipment, the average operating humidity of the automation equipment environment, the average operating speed of the automation equipment, the average operating current of the automation equipment, and the average operating voltage of the automation equipment, and calculates the health index of the automation equipment, where:

[0051] The calculation formula for the average operating temperature of automation equipment is as follows:

[0052]

[0053] The mean operating temperature can help determine the performance range of the device under normal working conditions. When the temperature fluctuates around the mean, it usually indicates that the device is operating normally. Conversely, if the temperature exceeds the normal range, it may cause the device to perform poorly, reduce efficiency, or shorten its life. In the formula, Indicates the average operating temperature of automation equipment. Represents the total number of measured temperature data points, Indicates The measured temperature data values, Indicates the count subscript. Monitoring the mean temperature helps to detect potential faults early. For example, if the mean gradually rises and approaches the maximum temperature limit of the equipment, this may be a sign of equipment overload or cooling system failure. Timely measures can avoid serious faults.

[0054] The calculation formula for the mean operating pressure of automation equipment is as follows:

[0055]

[0056] The mean pressure can indicate the stability and safety of the equipment during operation. Abnormal pressure may mean wear of mechanical parts, blockage or leakage of pipelines, which may affect the overall safety and reliability of the equipment. In the formula, Indicates the average operating pressure of automation equipment. Indicates the total number of measured pressure data points, Indicates The measured pressure data values, Indicates the serial number of the pressure data point. During the production process, the mean pressure management helps to maintain a stable production environment, prevent production defects, and ensure that product quality meets the standards;

[0057] The calculation formula for the average humidity of the operating environment of automation equipment is as follows:

[0058]

[0059] The mean humidity value can help monitor the stability of the working environment of the equipment. For equipment that needs to work within a specific humidity range, such as precision instruments and electronic components, controlling the ambient humidity is very important. In the formula, Indicates the average humidity of the operating environment of the automation equipment. Represents the total number of humidity data points measured, The count subscript representing the ambient humidity, Indicates A measured ambient humidity data value. High or low humidity ranges can have a negative impact on the device. High humidity may cause equipment corrosion, while low humidity may cause static electricity accumulation. By detecting the average humidity value, environmental conditions can be actively adjusted to optimize the service life of the device.

[0060] The calculation formula for the average speed of automation equipment is as follows:

[0061]

[0062] The average speed is an important indicator for evaluating whether a mechanical system is operating as expected. Monitoring the change in speed can help identify mechanical wear and other reliability issues and evaluate the performance of the equipment in real time. In the formula, Indicates the average speed of the automation equipment. Indicates the total number of speed data points measured, represents a count subscript, Indicates The measured speed data value can be used to appropriately adjust the equipment speed to keep it near the mean value, which helps to maximize energy utilization efficiency, reduce energy consumption and achieve economic benefits.

[0063] The calculation formula for the average operating current of automation equipment is as follows:

[0064]

[0065] Through the current average, the energy consumption trend of the equipment can be analyzed to identify whether the equipment is energy-efficient under specific working conditions and whether there is potential for power saving. In the formula, Indicates the average operating current of the automation equipment. Represents the total number of measured current data points, Indicates The square of the measured current data value, The count subscript indicates the number of current data. Abnormal fluctuations in the current mean may indicate excessive motor load, short circuit or other electrical faults. Early detection can provide timely response to reduce equipment damage and downtime.

[0066] The calculation formula for the average operating voltage of automation equipment is as follows:

[0067]

[0068] Monitoring the voltage mean can provide key information about power supply stability. Voltage fluctuations may cause equipment damage, so it is important to maintain a stable voltage mean. In the formula, Indicates the average operating voltage of automation equipment. Indicates the total number of measured voltage data points, Indicates The square of the measured voltage data value, The count subscript represents the number of voltage data. The analysis of the voltage mean can help optimize the electrical configuration of the equipment and adjust the operating voltage to ensure that the equipment operates in the optimal voltage range, thereby improving the overall energy efficiency.

[0069] The calculation formula of automation equipment health index is as follows:

[0070]

[0071] The equipment health index is a comprehensive score of multiple operating parameters, providing an intuitive understanding of the overall health of the equipment, facilitating decision-making and management. In the formula, Represents the automation equipment health index, , , , , , The weight coefficient representing the corresponding value can provide a quantitative basis for equipment maintenance, upgrade and replacement through the equipment health index, which helps to formulate more effective asset management strategies and reduce operational risks;

[0072] The calculation formula of the weight coefficient is as follows:

[0073]

[0074] In the formula, Indicates The weight coefficient of each indicator is , Indicates and The original data value of each variable, and the weight coefficient is dynamically calculated based on the real-time operation data of the equipment. That is to say, during the operation of the equipment, as the data of each indicator changes, the weight coefficient will also be adjusted accordingly. For example, if the temperature rises abnormally at a certain point in time, its weight in the health index calculation may increase, thereby more significantly affecting the result of the health index.

[0075] The monitoring and alarm module integrates a set of automation equipment health threshold system, which aims to monitor the health status of the equipment in real time and judge the operation status of the equipment by accurately comparing and analyzing the generated automation equipment health index. When the calculated result of the equipment health index exceeds the predetermined health threshold, the monitoring and alarm module will immediately trigger the early warning mechanism to mark the abnormality of the equipment, ensuring that the operator can respond quickly and reduce potential losses.

[0076] Specifically, the monitoring and alarm module performs real-time monitoring and data collection of multi-dimensional data (such as temperature, pressure, humidity, voltage, current, and speed), and uses data processing algorithms to regularly calculate the health index of the equipment. In this process, the health threshold is set to a key standard value derived from experience or based on historical data analysis to define the normal operating range of the equipment;

[0077] Once the equipment health index exceeds the threshold, the monitoring alarm module can send an immediate warning signal to the user interface module through various communication methods (such as email, SMS or mobile application push notification) to notify the operator to take corresponding measures. This early warning mechanism can achieve instant response, ensuring that the operator can take maintenance or repair measures in time when an abnormality occurs, thereby reducing the production risk caused by equipment failure;

[0078] The user interface module provides users with an intuitive and friendly operation interface, which is designed to display the data analysis results, monitoring status and real-time operation information of automation equipment. Through the modern graphical user interface (GUI) design, the module collects data from various sensors and monitoring modules, and clearly presents the health index of the equipment and various operating parameters (such as temperature, pressure, humidity, voltage, current and speed) to users through charts, dashboards and real-time data streams, so that users can quickly understand the equipment status and its changing trends;

[0079] When the monitoring alarm module issues a warning signal, the user interface module can receive this information in real time and highlight the relevant alarms of abnormal operation of the automation equipment on the user interface. After the abnormal state is identified, the system automatically analyzes the data generated by the fault, and the intelligent algorithm automatically recommends solutions based on historical data and fault modes. These solutions may include specific maintenance steps, inspection suggestions or adjustment measures for equipment operation. Users can quickly access relevant information through simple click operations;

[0080] In addition, the user interface module also supports interactive operations, allowing users to customize the monitoring interface according to their own needs, such as setting key indicators to be displayed, adjusting data update frequency, and selecting different data views (such as chart view, list view, etc.) to improve the user's operating experience and data acquisition efficiency. At the same time, the module also supports historical data query and analysis. Users can view operating data of different time periods to facilitate long-term trend analysis and equipment performance evaluation.

[0081] Through the comprehensive application of the above systems, a scientific assessment is provided for the status of automated equipment, significantly improving the response speed and processing efficiency of equipment failures.

[0082] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An Internet-based automation equipment data collection and analysis system, characterized by: It includes equipment data acquisition module, equipment data storage module, equipment data analysis module, monitoring alarm module and user interface module; The equipment data acquisition module collects the operating temperature, operating pressure, operating environment humidity, operating voltage, operating speed, operating current and operating status data of the automation equipment through the temperature sensor, humidity sensor, pressure sensor, speed sensor, voltage sensor, current sensor and automation equipment interface, and transmits them to the equipment data storage module through the MQTT Internet communication protocol; The device data storage module uses a relational database to store the data transmitted by the device data acquisition module; The equipment data analysis module retrieves the data in the equipment data storage module for analysis, calculates the average operating temperature of the automation equipment, the average operating pressure of the automation equipment, the average operating humidity of the automation equipment environment, the average operating speed of the automation equipment, the average operating current of the automation equipment, and the average operating voltage of the automation equipment, and calculates the health index of the automation equipment and sends it to the monitoring and alarm module; The monitoring and alarm module has a built-in automation equipment health threshold, analyzes and compares the automation equipment health index with the automation equipment health threshold, determines the operating status of the automation equipment, and sends a warning signal to the user interface module when an abnormality occurs; The user interface module provides an operation interface for the user, displays the data analysis results and monitoring status of the automation equipment, and displays solutions to abnormal operation of the automation equipment on the user operation interface according to the early warning signal.

2. The Internet-based automation equipment data collection and analysis system according to claim 1, characterized in that: The calculation formula for the mean operating temperature of the automation equipment is as follows: ； In the formula, Indicates the average operating temperature of automation equipment. Represents the total number of measured temperature data points, Indicates The measured temperature data values, Indicates a counting subscript.

3. The Internet-based automation equipment data collection and analysis system according to claim 2, characterized in that: The calculation formula of the mean operating pressure of the automation equipment is as follows: ； In the formula, Indicates the average operating pressure of automation equipment. Indicates the total number of measured pressure data points, Indicates The measured pressure data values, Indicates the sequence number of the pressure data point.

4. The Internet-based automation equipment data collection and analysis system according to claim 3, characterized in that: The calculation formula for the average humidity of the operating environment of the automation equipment is as follows: ； In the formula, Indicates the average humidity of the operating environment of the automation equipment. Represents the total number of humidity data points measured, The count subscript representing the ambient humidity, Indicates The measured ambient humidity data value.

5. The Internet-based automation equipment data collection and analysis system according to claim 4, characterized in that: The calculation formula for the average speed of the automation equipment is as follows: ； In the formula, Indicates the average speed of the automation equipment. Indicates the total number of speed data points measured, represents a count subscript, Indicates The measured speed data value.

6. The Internet-based automation equipment data collection and analysis system according to claim 5, characterized in that: The calculation formula of the average operating current of the automation equipment is as follows: ； In the formula, Indicates the average operating current of the automation equipment. Represents the total number of measured current data points, Indicates The square of the measured current data value, A count subscript indicating the number of current data.

7. The Internet-based automation equipment data collection and analysis system according to claim 6, characterized in that: The calculation formula of the average operating voltage of the automation equipment is as follows: ； In the formula, Indicates the average operating voltage of automation equipment. Indicates the total number of measured voltage data points, Indicates The square of the measured voltage data value, A count subscript indicating the number of voltage data.

8. The Internet-based automation equipment data collection and analysis system according to claim 7, characterized in that: The calculation formula of the automation equipment health index is as follows: ； In the formula, Represents the automation equipment health index, , , , , , Indicates the weight coefficient of the corresponding value.

9. The Internet-based automation equipment data collection and analysis system according to claim 8, characterized in that: The calculation formula of the weight coefficient is as follows: ； In the formula, Indicates The weight coefficient of each indicator is It indicates the normalized operating temperature, operating pressure, operating environment humidity, operating voltage, operating speed and operating current of the automation equipment. Represents the sum of all normalized index values, subscript From 1 to 6, where 6 is the total number of indicators, this sum represents the combined impact of all indicators and provides a benchmark to measure the relative weight of each indicator.

10. The Internet-based automation equipment data collection and analysis system according to claim 9, characterized in that: The operating conditions of the automation equipment are as follows: When the automation equipment health index When the calculated result is greater than the health threshold of the automation equipment, the monitoring alarm module will issue a warning signal. As a sign of abnormality in automation equipment.

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