Port automation equipment self-checking method and system and computer readable storage medium

Abstract

According to the port automation equipment self-checking method and system and the computer readable storage medium, the reliability and safety of port automation equipment are improved. Port automation equipment information is obtained through the data sensing unit, and the information can be obtained in real time or at regular time; the data sensing unit performs data interaction with the programmable logic controller to generate port automation equipment point location information, and the point location information comprises a fault point location, an operation data point location and a network communication point location; storing the point location information in a binary file mode; the point location information is shared to a database, and the database processes the data; and port automation equipment self-inspection information is generated, a self-inspection work order is initiated, and the self-inspection information is visually displayed.

Description

Technical Field

[0001] The present application relates to the field of automated docks, and in particular to a self-checking method and system for port automation equipment and a computer-readable storage medium. Background Art

[0002] At present, more and more traditional terminals are gradually transforming from traditional container terminals to automated ports by upgrading and renovating traditional equipment through automation. The port's employment model has changed accordingly. The remote operating drivers of automated equipment are concentrated in the automated operation center for many-to-many operation mode, which makes it impossible for remote operating drivers to go to the site to complete the daily safety and technical inspection process of large-scale operating machinery in accordance with the requirements of the on-site operation management system. The automated equipment cluster is centrally dispatched by the terminal's intelligent dispatching system for all-weather operations. If the daily safety and technical inspection process of large-scale operating machinery is not implemented, the reliability and safety of automated port equipment will be greatly reduced. The automated loading and unloading area is unsupervised, and it needs to be shut down for daily inspections, which affects production efficiency. Summary of the invention

[0003] The present invention aims to overcome at least one defect of the above-mentioned prior art, and provides a port automation equipment self-check method, system and computer-readable storage medium to improve the reliability and safety of the port automation equipment.

[0004] On the one hand, a port automation equipment self-checking method is provided, the method comprising:

[0005] Acquire port automation equipment information through data sensing units, and the information can be acquired in real time or at regular intervals;

[0006] The data sensing unit interacts with the programmable logic controller to generate port automation equipment point information, including fault points, operation data points, and network communication points;

[0007] Saving the point information in binary file format;

[0008] The point information is shared to a database, and the database processes the data;

[0009] Generate port automation equipment self-inspection information and initiate a self-inspection work order, wherein the self-inspection information is displayed visually.

[0010] On the one hand, a port automation equipment self-checking method is also provided, the method comprising:

[0011] Obtaining self-check information instructions for port automation equipment, wherein the self-check information includes real-time status information of the port automation equipment, pre-production operation detection information, and self-check analysis information;

[0012] Displaying early warning information of port automation equipment, wherein the early warning information is obtained based on the real-time status information of the port automation equipment;

[0013] Displaying the self-check analysis results of the port automation equipment, wherein the self-check analysis results of the port automation equipment are obtained by analyzing the historical data of the port automation equipment and the real-time status information of the port automation equipment;

[0014] Display the progress of fault handling, receive the port automation equipment warning information and the port automation equipment self-test analysis results, and display the progress of fault handling;

[0015] Obtaining detection information instructions for key parts of port automation equipment;

[0016] The detection results of the key parts are displayed, and the detection results include excellent, warning, and alarm.

[0017] On the one hand, a port automation equipment self-checking system is also provided, the system comprising:

[0018] System execution layer, the system execution layer is used for the data sensor unit to collect the mechanical and electrical status of the equipment, the operating environment, and the network communication information. The data sensor unit includes a tilt sensor, a PNP type proximity limiter, and a laser. The data sensor unit is connected to a programmable logic controller, and the programmable logic controller collects the data sensor unit in real time and outputs the corresponding status point data and fault self-detection point data;

[0019] System storage layer, the system storage layer is used for data storage, data classification, and data transmission, and the system storage layer receives point data;

[0020] System business layer, which is used to analyze the data information of the storage layer to obtain the self-test results of the port automation equipment, which include equipment status, yard information, and network communication information. The self-test results are compared with the set thresholds to obtain the equipment health status, fault type and frequency, and maintenance requirements;

[0021] The system application layer is used for visual self-check report display.

[0022] On the one hand, a computer-readable storage medium is also provided, storing a computer program, and when the computer program is executed by a processor, the processor executes the steps of the method.

[0023] The main advantages of the present invention are:

[0024] First, through digital and information-based self-inspection technology, remote control operators are assisted to automatically and intelligently complete the daily safety technical inspection of large-scale operating machinery, and the overall status of the port's automation equipment is provided before each shift of production.

[0025] Second, by testing the core control system, sensor system, key mechanism system and network system, the fault can be accurately located, and timely replacement or repair can be carried out to eliminate operational safety hazards.

[0026] Third, the automated port cranes self-check and analyze the massive monitoring data. During the automatic operation process, the automated port cranes generate massive monitoring data. The industrial Internet of Things transmission technology and data storage distribution technology are used to store, analyze and classify the equipment operation data, fault data and status data. Combined with the artificial intelligence data mining algorithm, the automated port cranes can realize self-check fault warning and trend analysis warning. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of a self-checking method for port automation equipment of the present invention.

[0028] Figure 2 It is a visualized schematic diagram of self-checking of a port automation equipment according to the present invention.

[0029] Figure 3 It is a schematic diagram of a port automation equipment self-checking system of the present invention. DETAILED DESCRIPTION

[0030] The drawings of the present invention are only for illustrative purposes and should not be construed as limiting the present invention. In order to better illustrate the following embodiments, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of the actual product; it is understandable to those skilled in the art that some well-known structures and their descriptions in the drawings may be omitted.

[0031] The present application embodiment provides a port automation equipment self-check method, such as Figure 1 , methods include:

[0032] S100: Acquire port automation equipment information through a data sensing unit, where the information can be acquired in real time or at a fixed time;

[0033] S102: The data sensing unit interacts with the programmable logic controller to generate port automation equipment point information, wherein the point information includes fault points, operation data points, and network communication points;

[0034] S104: Saving the point information in a binary file format;

[0035] S106: The point information is shared to a database, and the database processes the data;

[0036] S108: Generate port automation equipment self-inspection information and initiate a self-inspection work order, wherein the self-inspection information is displayed through visualization.

[0037] In S100, the data sensing unit is responsible for sensing on-board data, such as:

[0038] The tilt sensor is responsible for sensing the front and rear, left and right tilt angle data of the spreader and trolley frame, in degrees;

[0039] The vibration sensor probe is responsible for detecting the vibration values ​​of the lifting motor, lifting gearbox input shaft, lifting gearbox primary shaft, lifting gearbox secondary shaft, and lifting gearbox output shaft, including displacement, velocity, and acceleration, respectively expressed in mm, mm / s, and mm / s 2 express.

[0040] In S102, the data sensing unit exchanges data with the programmable logic controller (PLC) through Profibus-DP cables, super-class shielded network cables, etc. The PLC performs serial and parallel logic operations to form corresponding point information, which includes: fault points, operating data points, network communication points, etc. In S104, the point information is saved in the form of a binary file on the stand-alone computer of the automation equipment. In S106, a data sharing connection is made with the Redis\Myspl database through a stand-alone file sharing service, and the database classifies and stores the data. In S108, self-test information is generated, and the self-test information is displayed in a visual way, including self-test work orders, self-test parameters, etc.

[0041] In this embodiment, the self-checking method involves port automation equipment. There are many systems and equipment associated with the port during operation, especially large ports, which have gradually been covered by automation and intelligence. The interaction between equipment basically involves the whole process, such as loading and unloading of ships at or off the shore, which must be loaded and unloaded by the front quay crane, and the loading and unloading must be transported by intelligent guided vehicles, and transported to a specific yard and stacked by gantry cranes and other equipment, which involves terminal management systems, vehicle management systems, scheduling systems, work order systems, etc., and the port automation operation can be successfully completed after the interaction between multiple devices and multiple systems. In order to ensure the reliability and safety of port operation equipment, equipment detection is essential, but the business is busy and there are many types of equipment, so manual detection can no longer be completed, and automated ports basically adopt a 24-hour working mode.

[0042] In this embodiment, it is proposed to use a data sensing unit to obtain information about port automation equipment, and the information can be obtained in real time or at a fixed time, so that the overall real-time situation can be grasped while avoiding the waste of resources due to too frequent self-inspection. In addition, after obtaining the point information, the real-time situation of each device and each important component can be accurately located, and the situation of port automation equipment can be understood from the aspects of prevention, alarm, and maintenance. After obtaining the self-inspection information, there are also many ways to output it. In the field of automated ports, digital display is the best display method, which can intuitively view and control port equipment, reduce labor costs, and increase the reliability of port automation equipment.

[0043] In some embodiments, the present application also proposes a port automation equipment self-checking method, such as Figure 2 , the method comprising:

[0044] S200: obtaining a self-check information instruction for port automation equipment, wherein the self-check information includes real-time status information of the port automation equipment, pre-production operation detection information, and self-check analysis information;

[0045] S202: Displaying warning information of port automation equipment, where the warning information is obtained based on real-time status information of the port automation equipment;

[0046] S204: displaying the self-check analysis result of the port automation equipment, wherein the self-check analysis result of the port automation equipment is obtained by analyzing the historical data of the port automation equipment and the real-time status information of the port automation equipment;

[0047] S206: Displaying the progress of fault handling, receiving the port automation equipment warning information and the port automation equipment self-check analysis result, and displaying the progress of fault handling;

[0048] S208: Obtaining key parts detection information instructions of port automation equipment;

[0049] S210: Display the key part detection results, which include excellent, warning, and alarm.

[0050] In this embodiment, a port automation equipment self-inspection method is proposed, and a self-inspection function is realized through a self-inspection display platform.

[0051] Port automation equipment includes quay cranes, gantry cranes, yard cranes, rail cranes, trailers, forklifts and reach stackers. Each equipment includes key parts. For example, rail cranes include carts, trolleys, spreaders, pulleys, etc. The self-inspection information involved includes the number of operating boxes on the day, equipment status, trolley battery, lifting voltage, speed, heavy load impact, etc.

[0052] The self-inspection display platform includes sub-functions such as homepage, self-inspection report, fault code dictionary, self-inspection equipment, and PLC equipment. The homepage is used to display the self-inspection status of port automation equipment, including the test results of each device, which are quantitatively displayed by quantity. For example, the self-inspection status of the quay crane shows 57 excellent status, 3 warning status, and 1 alarm status; the self-inspection status of the trailer shows 588 excellent status, 22 warning status, and 3 alarm status. The self-inspection status is obtained by obtaining the information of port automation equipment through the data sensing unit. Specifically, the key components of each device are tested and the test data is collected and transmitted to the database. The platform is divided into different states according to the normal range of the parameters of each key component. For example, for the detection of motor temperature, different states correspond to different ranges. If it is an enumeration type, such as the brake function of the large vehicle, there are only qualified and unqualified test results. By testing the key components of each device, the overall status of each device is known, so that the self-inspection status of each device is displayed, so that the operator can intuitively view the status of each device. The display results can be viewed in real time or updated regularly. For the warning content, the display platform will display the corresponding equipment number, location, and warning content, and assign three levels: high, medium, and low. Operators will handle them in order according to the priority level. Those that do not affect the operation of the equipment will be cancelled and included in the subsequent observation. For those that need to be handled, a fault work order will be automatically generated and displayed on the display platform. The display content includes the repair content, corresponding number, fault content, and completion time. The corresponding number can be directly associated with the equipment and specific location.

[0053] When you choose to view the status of a single device, the display platform jumps to the relevant interface, which displays the status of each key component of the specific device. The operator can view it in real time or customize the inspection. For example, before the task starts, a self-inspection can be performed on a specific device or a specific key component, and the display platform updates the self-inspection results in a timely manner. In terms of historical data, the display platform provides displays of different periods, and can also query and export according to the operator's own settings to provide basic data for fault analysis. At the same time, the display platform uses historical data as a reference, intelligently analyzes whether the real-time self-inspection data is normal, and feedbacks the results.

[0054] Preferably, the warning information includes a warning level, and the warning level includes high, medium and low. The warning equipment can be processed according to different levels, and the emergency warning with high priority should be processed preferentially, so as to reduce losses and improve efficiency.

[0055] Preferably, the automation equipment self-check analysis results include the reliability, maintainability and utilization analysis results of the port automation equipment and key parts of the port automation equipment, and the analysis results are displayed through time trends. They can be displayed through charts or dynamic information, and the corresponding reliability, maintainability and utilization at different times can be observed.

[0056] Preferably, the method proposed in this embodiment also includes a digital twin display of the status of port automation equipment. Through the large-screen display, the port operation status can be understood in real time, and it can be highly restored to the on-site environment, and management can be convenient and intuitive. For example, for rail cranes operating in the yard, the operation status of each gantry crane can be displayed through digital twins, including which equipment is working, which equipment is idle, which equipment has faults, which equipment has warnings, etc., which can all be displayed on the screen. At the same time, the display platform also has the function of manual operation, and the operation can be adjusted manually.

[0057] In some embodiments, a port automation equipment self-checking system is also provided, such as Figure 3 , the system comprising:

[0058] System execution layer, the system execution layer is used for the data sensor unit to collect the mechanical and electrical status of the equipment, the operating environment, and the network communication information. The data sensor unit includes a tilt sensor, a PNP type proximity limiter, and a laser. The data sensor unit is connected to a programmable logic controller, and the programmable logic controller collects the data sensor unit in real time and outputs the corresponding status point data and fault self-detection point data;

[0059] System storage layer, the system storage layer is used for data storage, data classification, and data transmission, and the system storage layer receives point data;

[0060] System business layer, which is used to analyze the data information of the storage layer to obtain the self-test results of the port automation equipment, which include equipment status, yard information, and network communication information. The self-test results are compared with the set thresholds to obtain the equipment health status, fault type and frequency, and maintenance requirements;

[0061] The system application layer is used for visual self-check report display, including equipment self-check report, KPI operation statistics, etc.

[0062] The intelligent self-checking system of port automation equipment includes system execution layer, system business layer, system storage layer and system application layer.

[0063] In the system execution layer, there are 2 inclination sensors, 8 lasers, 5 absolute encoders, 24 cameras, 16 PNP proximity limit switches, 4 mechanical rocker limit switches, 24 vibration sensor probes, 2 cam limit switches, 1 overspeed switch and other data sensing units installed on the automation equipment. The installation locations cover every corner of the equipment. High-quality shielded cables and Category 6 shielded network cables are used to connect the data sensing units to the crane PLC controller. The PLC collects, analyzes, processes and calculates the sensor units in real time, and outputs the corresponding status points and fault self-check points.

[0064] The whole machine adopts industrial-grade data sensing units, which can reliably monitor the equipment status, yard conditions, and network communications in harsh application environments, and immediately terminate the operation of the automated container crane when an abnormal situation occurs. Data sensing units such as absolute encoders and trolley magnetic scale readers use high-quality Profibus-DP cables to interact with PLCs to obtain the position information of the whole machine; data sensing units such as lasers and cameras communicate with PLCs through super-class shielded network cables, and exchange data through interface protocols to obtain the whole machine environment image and yard container scanning data; proximity limiters are connected to the on-board relay unit through shielded cables, and the on and off of the relay corresponds to the on and off of the corresponding points of the PLC, ultimately achieving real-time monitoring of the equipment status, yard environment, and network communications. When an abnormal situation occurs, the corresponding detection point of the PLC is turned on, the automatic operation is terminated in time, and the time, type, and number of failures that occurred are recorded.

[0065] The system storage layer is used for local data and remote data communication, storage and processing, and to establish a fault code dictionary.

[0066] Use the relational database management system MySQL database to interact with PLC through the TCP network, and save the point data in different tables. For example: the parameter table (Device parameter) stores the equipment parameter points; the maintenance table (Operation and maintenance) stores the operation and maintenance parameter points; the self-test data table (Equipment Self-Test) stores the PLC fault points, operating environment, and network communication points. Connect the equipment status data in series to form a relatively complete record system, which is systematic, complete, and accurate, and is waiting for the system application layer to call.

[0067] The system business layer is used to analyze the data information of the storage layer to analyze and calculate the information detected at each point during automatic operation, and obtain the equipment status, yard conditions, and network communication conditions.

[0068] The point information is transmitted to the rear MySQL database through the network. The point information is stored, analyzed and calculated in real time in the corresponding table of the MySQL database in the order of the time of on and off. The information of each point is detected during automatic operation to achieve self-inspection of equipment health status, yard conditions, and network communication. By comparing and analyzing the self-inspection results with the set thresholds, the equipment health status, fault type and frequency, and maintenance demand decisions can be determined.

[0069] The system application layer is used to calculate visual self-inspection reports based on relevant data and specific formulas. That is, the equipment health status information, fault type, fault frequency, maintenance demand decision and other information are arranged uniformly from top to bottom in accordance with the table format, content, and time requirements of the automated container crane management regulations to form a self-inspection report for display.

[0070] It helps to reduce the workload of port managers and improve the intelligent level of port equipment loading and unloading management. According to the time sequence of the equipment self-checking points, the Bayesian algorithm is used to automatically analyze the equipment point fault data, accurately obtain the probability of the main cause of the equipment failure, and notify the equipment operators and on-site maintenance personnel through modern information transmission methods to close the loop of shutdown and technical maintenance in a timely manner, greatly reducing the workload of port managers.

[0071]

[0072] A is the first fault, B i This is a subsequent failure.

[0073] For example: Fault A is a lifting anti-collision detection failure, and fault B is a lifting encoder failure. A piece of equipment has experienced 10 lifting anti-collision failures and 8 lifting encoder failures in the past 24 hours. The probability of lifting encoder failure when a lifting anti-collision failure occurs is estimated to be 0.9. The question is: Which one is the main equipment failure, the lifting anti-collision failure or the lifting encoder failure?

[0074] Assuming that the statistics are in hours, P(A)=10 / 24=0.417, P(B)=8 / 24=0.334, P(A|B)=0.8, it is easy to get the result according to the formula: P(B|A)=0.9*0.334 / 0.417=0.721. Therefore, it can be concluded that the lifting anti-collision failure is the main cause of the failure, which needs to be focused on, and the direction of fault troubleshooting is clarified.

[0075] The complete and accurate record storage function helps to analyze the fault types and frequencies of port automation equipment, establish a fault code dictionary, and facilitate data storage and domain statistics.

[0076] In some embodiments, a computer-readable storage medium is also provided, storing a computer program, and when the computer program is executed by a processor, the processor executes the steps of the method.

[0077] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the technical solution of the present invention, and are not intended to limit the specific implementation methods of the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the claims of the present invention shall be included in the protection scope of the claims of the present invention.

Claims

1. A port automation equipment self-checking method, characterized in that: The method comprises: Acquire port automation equipment information through data sensing units, and the information can be acquired in real time or at regular intervals; The data sensing unit interacts with the programmable logic controller to generate port automation equipment point information, including fault points, operation data points, and network communication points; Saving the point information in binary file format; The point information is shared to a database, and the database processes the data; Generate port automation equipment self-inspection information and initiate a self-inspection work order, wherein the self-inspection information is displayed visually.

2. A port automation equipment self-checking method, characterized in that: The method comprises: Obtaining self-check information instructions for port automation equipment, wherein the self-check information includes real-time status information of the port automation equipment, pre-production operation detection information, and self-check analysis information; Displaying early warning information of port automation equipment, wherein the early warning information is obtained based on the real-time status information of the port automation equipment; Displaying the self-check analysis results of the port automation equipment, wherein the self-check analysis results of the port automation equipment are obtained by analyzing the historical data of the port automation equipment and the real-time status information of the port automation equipment; Display the progress of fault handling, receive the port automation equipment warning information and the port automation equipment self-test analysis results, and display the progress of fault handling; Obtaining detection information instructions for key parts of port automation equipment; The detection results of the key parts are displayed, and the detection results include excellent, warning, and alarm.

3. The method according to claim 2, characterized in that The method also includes displaying self-inspection information of port automation equipment, and the port automation equipment includes quay cranes, gantry cranes, yard cranes, rail cranes, trailers, forklifts, and reach cranes.

4. The method according to claim 2, characterized in that: The warning information includes a warning level, and the warning level includes high, medium, and low.

5. The method according to claim 2, characterized in that: The automation equipment self-check analysis results include reliability, maintainability and utilization analysis results of the port automation equipment and key parts of the port automation equipment, and the analysis results are displayed through time trends.

6. The method according to claim 2, characterized in that The method also includes a digital twin display of the status of the port automation equipment.

7. A port automation equipment self-checking system, characterized in that: The system comprises: System execution layer, the system execution layer is used for the data sensor unit to collect the mechanical and electrical status of the equipment, the operating environment, and the network communication information. The data sensor unit includes a tilt sensor, a PNP type proximity limiter, and a laser. The data sensor unit is connected to a programmable logic controller, and the programmable logic controller collects the data sensor unit in real time and outputs the corresponding status point data and fault self-detection point data; System storage layer, the system storage layer is used for data storage, data classification, and data transmission, and the system storage layer receives point data; System business layer, which is used to analyze the data information of the storage layer to obtain the self-test results of the port automation equipment, which include equipment status, yard information, and network communication information. The self-test results are compared with the set thresholds to obtain the equipment health status, fault type and frequency, and maintenance requirements; The system application layer is used for visual self-check report display.

8. The system according to claim 7, characterized in that The fault self-checking points are used to obtain the probability of the cause of the equipment failure through the Bayesian algorithm according to the time sequence of the equipment self-checking points.

9. The system according to claim 7, characterized in that The system also includes establishing a fault code dictionary.

10. A computer-readable storage medium storing a computer program, wherein when the computer program is executed by a processor, the processor executes the steps of the method according to any one of claims 1 to 6.

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