Monitoring system and method for spinning production

Abstract

The invention discloses a monitoring system and method for spinning production, and relates to the technical field of spinning monitoring, and the method comprises the steps: obtaining the data of a spinning machine through an equipment safety monitoring management module, a current sensor and the like, and calculating the operation efficiency and comprehensive energy consumption to judge the operation state; the manual safety monitoring management module is used for acquiring worker data by means of an intelligent bracelet, a camera and an intelligent safety helmet, calculating physiological and behavior safety coefficients, evaluating the safety coefficient of the worker and judging a danger level; the environment safety monitoring management module evaluates fire-fighting related factors of the spinning workshop to obtain an environment safety coefficient, and judges whether the workshop environment is safe or not. According to the system and the method, multi-dimensional monitoring of spinning production is realized, and production safety and efficiency are guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of spinning monitoring, and in particular to a monitoring system and method for spinning production. Background Art

[0002] Various types of textiles made of yarn are an indispensable part of people's daily lives. The spinning machine is a device composed of multiple complex mechanical parts and electrical systems. In the spinning production process, the stable operation of the equipment, the control of yarn quality and the suitability of the production environment are crucial to product quality and production efficiency. Traditional spinning production lacks comprehensive, real-time and accurate monitoring methods, and it is difficult to detect potential equipment failures at an early stage, resulting in production interruptions and affecting production progress; for yarn quality fluctuations, it is impossible to trace the root causes of the problems in the production process in time, resulting in a large number of defective products; at the same time, it is impossible to control the production environment in real time, affecting yarn performance and production stability. Therefore, it is particularly important to invent a monitoring system and method for spinning production.

[0003] The existing technology also has the following defects, which are specifically reflected in: 1. In the existing technology, in terms of equipment safety monitoring and management, the analysis is centered on rollers and spindles, and not much attention is paid to the operating efficiency and comprehensive energy consumption of the spinning machine. It is impossible to accurately evaluate whether the spinning machine is in the best operating state as a whole, and it is difficult to improve energy utilization efficiency, resulting in energy waste, which does not meet the requirements of sustainable development.

[0004] 2. In the existing technology, in environmental safety monitoring and management, analysis is conducted around temperature, humidity, dust concentration, and harmful gas concentration, but little attention is paid to various fire-fighting measures in the spinning workshop. It is impossible to fully understand the environmental safety level of the workshop, resulting in an underestimation of the overall safety risks. There are a large number of flammable fiber materials in the spinning workshop, and fire-fighting facilities such as expired fire extinguishers and damaged fire hydrants cannot be discovered in time, resulting in the company's failure to meet regulatory standards and facing legal risks such as administrative penalties, which affects the company's normal operations and reputation. Summary of the invention

[0005] The purpose of the present invention is to provide a monitoring system and method for spinning production, which solves the problems existing in the background technology.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solution: The present invention provides a monitoring system for spinning production, including: an equipment safety monitoring and management module, which is used to obtain relevant data of each spinning machine during the spinning process, calculate the operating efficiency and comprehensive energy consumption of each spinning machine, and then determine whether each spinning machine is in a normal operating state.

[0007] The manual safety monitoring and management module is used to obtain relevant data of each worker in the spinning process, calculate the physiological safety factor of each worker, calculate the behavioral safety factor of each worker, and then evaluate the safety factor of each worker and determine the danger level of each worker.

[0008] The environmental safety monitoring and management module is used to obtain relevant data of the spinning workshop, evaluate the environmental safety factor of the spinning workshop, and then determine whether the spinning workshop environment is safe.

[0009] The display terminal is used to display the operating efficiency and comprehensive energy consumption of each spinning machine, the danger level of each worker, and the environmental safety factor of the spinning workshop.

[0010] Preferably, the calculation of the operating efficiency and comprehensive energy consumption of each spinning machine is specifically analyzed by: obtaining the current in the total circuit of each spinning machine through a current sensor; if the current in the total circuit of the spinning machine is within the preset working current range of the spinning machine, the spinning machine is determined to be in an operating state; if the current in the circuit is not within the preset working current range of the spinning machine, the spinning machine is determined to be in a stopped state; and the actual operating time of each spinning machine is obtained by recording the duration of the current, which is compared with the operating time of the spinning machine preset based on the production plan to obtain the operating efficiency of each spinning machine.

[0011] The current of each spinning machine at each sampling time point is obtained through the current sensor, the voltage of each spinning machine at each sampling time point is obtained through the voltage sensor, and the power factor of each spinning machine at each sampling time point is obtained through the power factor sensor. The comprehensive energy consumption of each spinning machine is calculated, and the calculation formula is: where α p represents the comprehensive energy consumption of the pth spinning machine, V pi represents the voltage of the p-th spinning machine at the i-th sampling time point, I pi represents the current of the pth spinning machine at the i-th sampling time point, cosR pi represents the power factor of the pth spinning machine at the i-th sampling time point, T p represents the actual running time of the pth spinning machine, i represents the number of the sampling time point, i=1,2,...,j, j is a positive integer greater than 2, p represents the number of the spinning machine, p=1,2,...,q, q is a positive integer greater than 2.

[0012] Preferably, the specific analysis method for judging whether each spinning machine is in a normal operating state is as follows: extracting the operating efficiency and comprehensive energy consumption of each spinning machine, and comparing them with the suitable operating efficiency range and the suitable comprehensive energy consumption range of the spinning machine stored in the database respectively; if the operating efficiency of a spinning machine is within the suitable operating efficiency range of the spinning machine stored in the database and the comprehensive energy consumption of the spinning machine is within the suitable comprehensive energy consumption range of the spinning machine stored in the database, then it is determined that the spinning machine is in a normal operating state; if the operating efficiency of a spinning machine is not within the suitable operating efficiency range of the spinning machine stored in the database or the comprehensive energy consumption of the spinning machine is not within the suitable comprehensive energy consumption range of the spinning machine stored in the database, then it is determined that the spinning machine is in an abnormal operating state.

[0013] Preferably, the physiological safety factor of each worker is calculated by a specific analysis method: the heart rate and blood pressure of each worker during the spinning process are obtained through a smart bracelet, and then the physiological safety factor of each worker is calculated. The calculation formula is: where β m represents the physiological safety factor of the mth worker, b m represents the heart rate of the mth worker during the spinning process, c m represents the blood pressure of the mth worker during the spinning process, b′ and c′ represent the appropriate heart rate range and the appropriate blood pressure range stored in the database, m represents the number of each worker, m=1,2,...,n, n is a positive integer greater than 2, e represents a natural constant, φ1 and φ2 represent the appropriate heart rate safety weight factor and the appropriate blood pressure safety weight factor stored in the database respectively.

[0014] Preferably, the specific analysis method for calculating the behavioral safety factor of each worker is as follows: through a camera, the virtual boundary coordinates of each dangerous area are set, and through a smart bracelet, the coordinates of each worker in the spinning process are obtained. When the coordinates of a worker in the spinning process appear within the virtual boundary coordinates of a dangerous area, the system automatically starts timing, stops timing when leaving, and automatically counts the length of time the worker stays in each dangerous area to obtain the length of time each worker stays in the dangerous area during the spinning process. Through the smart bracelet, the total working time of each worker is obtained, and then the exposure time ratio of each worker in the spinning process is obtained. Through the smart safety helmet, the number of collisions of each worker in the spinning process is obtained, and then the behavioral safety factor of each worker is calculated. The calculation formula is: where χ m represents the behavioral safety factor of the mth worker, a m represents the number of collisions of the mth worker during the spinning process, g m It represents the exposure time proportion of the mth worker in the spinning process.

[0015] Preferably, the safety factor of each worker is evaluated by a specific analysis method: taking the production batch as the statistical unit, obtaining the total number of spinning production batches completed within a preset time period from the database, obtaining the number of safety accidents occurring in the spinning workshop within the preset time period, and then calculating the safety accident rate of the spinning workshop, and the calculation formula is: Wherein δ represents the occurrence rate of safety accidents in the spinning workshop, f represents the number of safety accidents occurring in the spinning workshop within a preset time period, and f′ represents the total number of spinning production batches completed within the preset time period.

[0016] Extract the physiological safety factor and behavioral safety factor of each worker, and then evaluate the safety factor of each worker. The calculation formula is: where μ m represents the safety factor of the mth worker, γ1 and γ2 represent the appropriate physiological safety factor weight factor and the appropriate behavioral safety factor weight factor stored in the database, respectively.

[0017] Preferably, the specific analysis method for determining the danger level of each worker is as follows: extracting the safety factor of each worker, and comparing it with the worker safety factor ranges corresponding to each danger level stored in the database; if the safety factor of a worker is within the worker safety factor range corresponding to the low-risk danger level, then the danger level of the worker is determined to be low risk; if the safety factor of a worker is within the worker safety factor range corresponding to the medium-risk danger level, then the danger level of the worker is determined to be medium risk; if the safety factor of a worker is within the worker safety factor range corresponding to the high-risk danger level, then the danger level of the worker is determined to be high risk.

[0018] Preferably, the evaluation of the environmental safety factor of the spinning workshop is carried out by a specific analysis method: obtaining various fire-fighting measures in the spinning workshop, evaluating the integrity of fire-fighting measures equipment, the functional effectiveness of fire-fighting facilities, the rationality of fire-fighting facilities layout, the smooth flow of fire-fighting passages and the maintenance and management coefficient of fire-fighting facilities, and then evaluating the environmental safety factor of the spinning workshop. The calculation formula is: F=w1*ρ1+w2*ρ2+w3*ρ3+w4*ρ4+w5*ρ5, wherein F represents the environmental safety factor of the spinning workshop, w1, w2, w3, w4, and w5 respectively represent the fire-fighting measures equipment integrity, the functional effectiveness of fire-fighting facilities, the rationality of fire-fighting facilities layout, the smooth flow of fire-fighting passages and the maintenance and management coefficient of fire-fighting facilities in the spinning workshop, and ρ1, ρ2, ρ3, ρ4, and ρ5 respectively represent the appropriate fire-fighting measures equipment integrity weight factor, the appropriate fire-fighting facilities functional effectiveness weight factor, the appropriate fire-fighting facilities layout rationality weight factor, the appropriate fire-fighting passage smoothness weight factor and the appropriate fire-fighting facilities maintenance and management coefficient weight factor stored in the database.

[0019] Preferably, the specific analysis method for judging whether the spinning workshop environment is safe is: extracting the spinning workshop environmental safety factor, and comparing it with the spinning workshop environmental safety factor threshold stored in the database; if the spinning workshop environmental safety factor is lower than the spinning workshop environmental safety factor threshold stored in the database, then the spinning workshop environment is judged to be unsafe; if the spinning workshop environmental safety factor is higher than the spinning workshop environmental safety factor threshold stored in the database, then the spinning workshop environment is judged to be safe.

[0020] A second aspect of the present invention includes a method of a monitoring system for spinning production, comprising:

[0021] Step 1: Equipment safety monitoring and management, obtain relevant data of each spinning machine during the spinning process, calculate the operating efficiency and comprehensive energy consumption of each spinning machine, and then determine whether each spinning machine is in normal operating state.

[0022] Step 2: Manual safety monitoring and management: obtain relevant data of each worker in the spinning process, calculate the physiological safety factor of each worker, calculate the behavioral safety factor of each worker, and then evaluate the safety factor of each worker to determine the danger level of each worker.

[0023] Step three, environmental safety monitoring and management, obtain relevant data of the spinning workshop, evaluate the environmental safety factor of the spinning workshop, and then determine whether the spinning workshop environment is safe.

[0024] The beneficial effects of the present invention are: 1. In the present invention, the attention paid to the operating efficiency and comprehensive energy consumption of the spinning machine is increased, and the spinning machine with low operating efficiency can be discovered in time to avoid production stagnation caused by equipment failure or poor operation, thereby improving the efficiency of the spinning production as a whole, helping to arrange production tasks more reasonably according to the actual production capacity, ensuring the smooth completion of the production plan, and improving the utilization rate of the equipment.

[0025] 2. In the present invention, increased attention is paid to various fire-fighting measures in the spinning workshop, which helps to ensure the continuity of production, reduce the production interruption time caused by fire, avoid serious impact on the company's production plan and order delivery, and avoid the legal risks faced by the company due to violation of fire regulations. It reflects the company's emphasis on employee life safety and social responsibility, helps to enhance the company's social image and reputation, and enhances the trust of customers, partners and the public in the company. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0027] Figure 1 It is a schematic diagram of the system structure connection of the present invention.

[0028] Figure 2 The present invention is a schematic flow chart of the steps for implementing the method. DETAILED DESCRIPTION

[0029] 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.

[0030] Reference Figure 1 As shown, the present invention provides a monitoring system for spinning production, including: an equipment safety monitoring and management module, which is used to obtain relevant data of each spinning machine during the spinning process, calculate the operating efficiency and comprehensive energy consumption of each spinning machine, and then determine whether each spinning machine is in a normal operating state.

[0031] It should be noted that the relevant data of each spinning machine include current, voltage and power factor.

[0032] In a specific embodiment, the operation efficiency and comprehensive energy consumption of each spinning machine are calculated by a specific analysis method as follows: the current in the total circuit of each spinning machine is obtained through a current sensor; if the current in the total circuit of the spinning machine is within a preset working current range of the spinning machine, the spinning machine is determined to be in operation; if the current in the circuit is not within the preset working current range of the spinning machine, the spinning machine is determined to be in a stopped state; the actual operation time of each spinning machine is obtained by recording the duration of the current; the actual operation time of each spinning machine is compared with the operation time of the spinning machine preset based on the production plan to obtain the operation efficiency of each spinning machine.

[0033] It should be noted that the preset working current range of the spinning machine and the preset running time of the spinning machine are set by professionals.

[0034] The current of each spinning machine at each sampling time point is obtained through the current sensor, the voltage of each spinning machine at each sampling time point is obtained through the voltage sensor, and the power factor of each spinning machine at each sampling time point is obtained through the power factor sensor. The comprehensive energy consumption of each spinning machine is calculated, and the calculation formula is: where α p represents the comprehensive energy consumption of the pth spinning machine, V pi represents the voltage of the p-th spinning machine at the i-th sampling time point, I pi represents the current of the pth spinning machine at the i-th sampling time point, cosR pi represents the power factor of the pth spinning machine at the i-th sampling time point, T p represents the actual running time of the pth spinning machine, i represents the number of the sampling time point, i=1,2,...,j, j is a positive integer greater than 2, p represents the number of the spinning machine, p=1,2,...,q, q is a positive integer greater than 2.

[0035] In the present invention, more attention is paid to the operating efficiency and comprehensive energy consumption of the spinning machine, and spinning machines with low operating efficiency can be discovered in time to avoid production stagnation due to equipment failure or poor operation, thereby improving the efficiency of spinning production as a whole, helping to arrange production tasks more reasonably according to actual production capacity, ensuring the smooth completion of production plans, and improving equipment utilization.

[0036] In a specific embodiment, the determination of whether each spinning machine is in a normal operating state is performed by a specific analysis method as follows: extracting the operating efficiency and comprehensive energy consumption of each spinning machine, and comparing them with the appropriate operating efficiency range and the appropriate comprehensive energy consumption range of the spinning machine stored in the database, respectively; if the operating efficiency of a spinning machine is within the appropriate operating efficiency range of the spinning machine stored in the database and the comprehensive energy consumption of the spinning machine is within the appropriate comprehensive energy consumption range of the spinning machine stored in the database, then it is determined that the spinning machine is in a normal operating state; if the operating efficiency of a spinning machine is not within the appropriate operating efficiency range of the spinning machine stored in the database or the comprehensive energy consumption of the spinning machine is not within the appropriate comprehensive energy consumption range of the spinning machine stored in the database, then it is determined that the spinning machine is in an abnormal operating state.

[0037] It should be noted that the appropriate operating efficiency range of the spinning machine and the appropriate comprehensive energy consumption range of the spinning machine stored in the database are set by professionals.

[0038] The manual safety monitoring and management module is used to obtain relevant data of each worker in the spinning process, calculate the physiological safety factor of each worker, calculate the behavioral safety factor of each worker, and then evaluate the safety factor of each worker and determine the danger level of each worker.

[0039] It should be noted that the relevant data of each worker in the spinning process include the worker's heart rate, blood pressure, length of stay in the danger zone, and number of collisions during the spinning process.

[0040] In a specific embodiment, the physiological safety factor of each worker is calculated by a specific analysis method: the heart rate and blood pressure of each worker during the spinning process are obtained through a smart bracelet, and then the physiological safety factor of each worker is calculated. The calculation formula is: where β m represents the physiological safety factor of the mth worker, b m represents the heart rate of the mth worker during the spinning process, c m represents the blood pressure of the mth worker during the spinning process, b′ and c′ represent the appropriate heart rate range and the appropriate blood pressure range stored in the database, m represents the number of each worker, m=1,2,...,n, n is a positive integer greater than 2, e represents a natural constant, φ1 and φ2 represent the appropriate heart rate safety weight factor and the appropriate blood pressure safety weight factor stored in the database respectively.

[0041] It should be noted that the appropriate heart rate range and the appropriate blood pressure range stored in the database, and the appropriate heart rate safety weight factor and the appropriate blood pressure safety weight factor stored in the database are set by professionals.

[0042] In a specific embodiment, the calculation of the behavioral safety factor of each worker is performed by a specific analysis method: through a camera, the virtual boundary coordinates of each dangerous area are set, and the coordinates of each worker in the spinning process are obtained through a smart bracelet. When the coordinates of a worker in the spinning process appear within the virtual boundary coordinates of a dangerous area, the system automatically starts timing, stops timing when leaving, and automatically counts the length of time the worker stays in each dangerous area to obtain the length of time each worker stays in the dangerous area during the spinning process. Through the smart bracelet, the total working time of each worker is obtained, and then the exposure time ratio of each worker in the spinning process is obtained. Through the smart safety helmet, the number of collisions of each worker in the spinning process is obtained, and then the behavioral safety factor of each worker is calculated. The calculation formula is: where χ m represents the behavioral safety factor of the mth worker, a m represents the number of collisions of the mth worker during the spinning process, g m It represents the exposure time proportion of the mth worker in the spinning process.

[0043] It should be noted that the virtual boundary coordinates of each dangerous area are set by shooting a calibration object of known size and shape, obtaining the internal parameters of the camera such as focal length, optical center position, etc. and external parameters such as rotation and translation relationship, determining the imaging model of the camera, so as to convert the pixel coordinates in the image into actual physical coordinates, obtaining the video stream of the spinning workshop from the camera, selecting a key frame containing a complete dangerous area with a clear image and no obstruction as the basic image for setting the virtual boundary, and using the drawing tool of the software to draw a virtual boundary along the edge of the dangerous area on the selected image. You can use the polygon drawing tool, according to the shape of the dangerous area, click point by point to determine the vertex of the boundary, the software will automatically connect these points to form a closed virtual boundary, after the drawing is completed, the software can usually provide the pixel coordinate information of the boundary vertex. If it is necessary to convert to actual physical coordinates, the pixel coordinates can be converted to actual physical coordinates through a coordinate conversion algorithm based on the previous camera calibration results and known scene size information.

[0044] In a specific embodiment, the safety factor of each worker is evaluated by a specific analysis method: taking the production batch as the statistical unit, obtaining the total number of spinning production batches completed within a preset time period from the database, obtaining the number of safety accidents occurring in the spinning workshop within the preset time period, and then calculating the safety accident rate in the spinning workshop. The calculation formula is: Wherein δ represents the occurrence rate of safety accidents in the spinning workshop, f represents the number of safety accidents occurring in the spinning workshop within a preset time period, and f′ represents the total number of spinning production batches completed within the preset time period.

[0045] It should be noted that the safety accidents include casualties and equipment failures.

[0046] Extract the physiological safety factor and behavioral safety factor of each worker, and then evaluate the safety factor of each worker. The calculation formula is: where μ m represents the safety factor of the mth worker, γ1 and γ2 represent the appropriate physiological safety factor weight factor and the appropriate behavioral safety factor weight factor stored in the database, respectively.

[0047] It should be noted that the preset time period, the appropriate physiological safety factor weighting factor, and the appropriate behavioral safety factor weighting factor stored in the database are set by professionals.

[0048] In a specific embodiment, the specific analysis method for determining the danger level of each worker is as follows: extracting the safety factor of each worker, and comparing it with the worker safety factor ranges corresponding to each danger level stored in the database; if a worker's safety factor is within the worker safety factor range corresponding to the low-risk danger level, then the worker's danger level is determined to be low risk; if a worker's safety factor is within the worker safety factor range corresponding to the medium-risk danger level, then the worker's danger level is determined to be medium risk; if a worker's safety factor is within the worker safety factor range corresponding to the high-risk danger level, then the worker's danger level is determined to be high risk.

[0049] It should be noted that the worker safety factor range corresponding to each hazard level stored in the database is set by professionals.

[0050] The environmental safety monitoring and management module is used to obtain relevant data of the spinning workshop, evaluate the environmental safety factor of the spinning workshop, and then determine whether the spinning workshop environment is safe.

[0051] It should be noted that the relevant data of the spinning workshop includes the types of fire-fighting facilities.

[0052] In a specific embodiment, the evaluation of the environmental safety factor of the spinning workshop is carried out by a specific analysis method: various fire-fighting measures in the spinning workshop are obtained, and the integrity of the fire-fighting measures equipment, the functional effectiveness of the fire-fighting facilities, the rationality of the layout of the fire-fighting facilities, the smooth flow of fire-fighting passages and the maintenance and management coefficient of the fire-fighting facilities are evaluated, and then the environmental safety factor of the spinning workshop is evaluated. The calculation formula is: F=w1*ρ1+w2*ρ2+w3*ρ3+w4*ρ4+w5*ρ5, wherein F represents the environmental safety factor of the spinning workshop, w1, w2, w3, w4, and w5 respectively represent the fire-fighting measures equipment integrity, the functional effectiveness of the fire-fighting facilities, the rationality of the layout of the fire-fighting facilities, the smooth flow of fire-fighting passages and the maintenance and management coefficient of the fire-fighting facilities in the spinning workshop, and ρ1, ρ2, ρ3, ρ4, and ρ5 respectively represent the appropriate fire-fighting measures equipment integrity weight factor, the appropriate fire-fighting facilities functional effectiveness weight factor, the appropriate fire-fighting facilities layout rationality weight factor, the appropriate fire-fighting passage smoothness weight factor and the appropriate fire-fighting facilities maintenance and management coefficient weight factor stored in the database.

[0053] In the present invention, increased attention is paid to various fire-fighting measures in the spinning workshop, which helps to ensure the continuity of production, reduce the production interruption time caused by fire, avoid serious impact on the company's production plan and order delivery, and can avoid the legal risks faced by the company due to violation of fire regulations. It reflects the company's emphasis on employee life safety and social responsibility, helps to enhance the company's social image and reputation, and enhances the trust of customers, partners and the general public in the company.

[0054] It should be noted that the specific analysis method for evaluating the integrity of fire-fighting equipment is as follows: clarify the types of fire-fighting facilities that should be equipped in the spinning workshop, generally including fire extinguishers, fire hydrants, emergency lighting and evacuation signs, etc., obtain the number of functional equipment of each fire-fighting facility, obtain the total number of equipment of each fire-fighting facility, and compare them to obtain the integrity of the fire-fighting equipment. The analysis methods for the effectiveness of the fire-fighting facilities, the rationality of the layout of the fire-fighting facilities, the unobstructedness of the fire-fighting passages and the maintenance and management coefficient of the fire-fighting facilities are the same as above and will not be repeated here. The appropriate weight factors for the integrity of fire-fighting equipment, the appropriate weight factors for the effectiveness of the fire-fighting facilities, the appropriate weight factors for the rationality of the layout of the fire-fighting facilities, the appropriate weight factors for the unobstructedness of the fire-fighting passages and the appropriate weight factors for the maintenance and management coefficient of the fire-fighting facilities stored in the database are set by professionals.

[0055] In a specific embodiment, the specific analysis method for judging whether the spinning workshop environment is safe is: extracting the spinning workshop environmental safety factor, and comparing it with the spinning workshop environmental safety factor threshold stored in the database; if the spinning workshop environmental safety factor is lower than the spinning workshop environmental safety factor threshold stored in the database, then the spinning workshop environment is judged to be unsafe; if the spinning workshop environmental safety factor is higher than the spinning workshop environmental safety factor threshold stored in the database, then the spinning workshop environment is judged to be safe.

[0056] It should be noted that the threshold value of the spinning workshop environmental safety factor stored in the database is set by professionals.

[0057] The display terminal is used to display the operating efficiency and comprehensive energy consumption of each spinning machine, the danger level of each worker, and the environmental safety factor of the spinning workshop.

[0058] The equipment safety monitoring and management module is connected to the manual safety monitoring and management module, the manual safety monitoring and management module is connected to the environmental safety monitoring and management module, and the manual safety monitoring and management module, the environmental safety monitoring and management module, and the environmental safety monitoring and management module are simultaneously connected to the display terminal and the database.

[0059] refer to Figure 2 , a method for a monitoring system for spinning production, comprising:

[0060] Step 1: Equipment safety monitoring and management, obtain relevant data of each spinning machine during the spinning process, calculate the operating efficiency and comprehensive energy consumption of each spinning machine, and then determine whether each spinning machine is in normal operating state.

[0061] Step 2: Manual safety monitoring and management: obtain relevant data of each worker in the spinning process, calculate the physiological safety factor of each worker, calculate the behavioral safety factor of each worker, and then evaluate the safety factor of each worker to determine the danger level of each worker.

[0062] Step three, environmental safety monitoring and management, obtain relevant data of the spinning workshop, evaluate the environmental safety factor of the spinning workshop, and then determine whether the spinning workshop environment is safe.

[0063] The above contents are merely examples and explanations of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, they shall all fall within the protection scope of the present invention.

Claims

1. A monitoring system for spinning production, characterized in that: include: Equipment safety monitoring and management module, used to obtain relevant data of each spinning machine during the spinning process, calculate the operating efficiency and comprehensive energy consumption of each spinning machine, and then determine whether each spinning machine is in normal operating state; The manual safety monitoring and management module is used to obtain the relevant data of each worker in the spinning process, calculate the physiological safety factor of each worker, calculate the behavioral safety factor of each worker, and then evaluate the safety factor of each worker and determine the danger level of each worker; Environmental safety monitoring and management module, which is used to obtain relevant data of the spinning workshop, evaluate the environmental safety factor of the spinning workshop, and then determine whether the spinning workshop environment is safe; The display terminal is used to display the operating efficiency and comprehensive energy consumption of each spinning machine, the danger level of each worker, and the environmental safety factor of the spinning workshop.

2. A monitoring system for spinning production according to claim 1, characterized in that: The specific analysis method for calculating the operating efficiency and comprehensive energy consumption of each spinning machine is as follows: The current in the total circuit of each spinning machine is obtained through a current sensor. If the current in the total circuit of the spinning machine is within the preset working current range of the spinning machine, it is determined that the spinning machine is in operation. If the current in the circuit is not within the preset working current range of the spinning machine, it is determined that the spinning machine is in a stopped state. By recording the duration of the current, the actual operating time of each spinning machine is obtained, which is compared with the operating time of the spinning machine preset based on the production plan to obtain the operating efficiency of each spinning machine. The current of each spinning machine at each sampling time point is obtained through the current sensor, the voltage of each spinning machine at each sampling time point is obtained through the voltage sensor, and the power factor of each spinning machine at each sampling time point is obtained through the power factor sensor. The comprehensive energy consumption of each spinning machine is calculated, and the calculation formula is: where α p represents the comprehensive energy consumption of the pth spinning machine, V pi represents the voltage of the p-th spinning machine at the i-th sampling time point, I pi represents the current of the pth spinning machine at the i-th sampling time point, cosR pi represents the power factor of the pth spinning machine at the i-th sampling time point, T p represents the actual running time of the pth spinning machine, i represents the number of the sampling time point, i=1,2,...,j, j is a positive integer greater than 2, p represents the number of the spinning machine, p=1,2,...,q, q is a positive integer greater than 2.

3. A monitoring system for spinning production according to claim 2, characterized in that: The specific analysis method for judging whether each spinning machine is in a normal operating state is as follows: The operating efficiency and comprehensive energy consumption of each spinning machine are extracted, and compared with the appropriate operating efficiency range of the spinning machine and the appropriate comprehensive energy consumption range of the spinning machine stored in the database. If the operating efficiency of a spinning machine is within the appropriate operating efficiency range of the spinning machine stored in the database and the comprehensive energy consumption of the spinning machine is within the appropriate comprehensive energy consumption range of the spinning machine stored in the database, then it is determined that the spinning machine is in a normal operating state; if the operating efficiency of a spinning machine is not within the appropriate operating efficiency range of the spinning machine stored in the database or the comprehensive energy consumption of the spinning machine is not within the appropriate comprehensive energy consumption range of the spinning machine stored in the database, then it is determined that the spinning machine is in an abnormal operating state.

4. A monitoring system for spinning production according to claim 1, characterized in that: The specific analysis method for calculating the physiological safety factor of each worker is as follows: Through the smart bracelet, the heart rate and blood pressure of each worker during the spinning process are obtained, and then the physiological safety factor of each worker is calculated. The calculation formula is: where β m represents the physiological safety factor of the mth worker, b m represents the heart rate of the mth worker during the spinning process, c m represents the blood pressure of the mth worker during the spinning process, b′ and c′ represent the appropriate heart rate range and the appropriate blood pressure range stored in the database, m represents the number of each worker, m=1,2,...,n, n is a positive integer greater than 2, e represents a natural constant, φ1 and φ2 represent the appropriate heart rate safety weight factor and the appropriate blood pressure safety weight factor stored in the database respectively.

5. A monitoring system for spinning production according to claim 4, characterized in that: The specific analysis method for calculating the behavior safety factor of each worker is as follows: Through the camera, the virtual boundary coordinates of each dangerous area are set, and the coordinates of each worker in the spinning process are obtained through the smart bracelet. When the coordinates of a worker in the spinning process appear in the virtual boundary coordinates of a dangerous area, the system automatically starts timing, stops timing when leaving, and automatically counts the length of time the worker stays in each dangerous area to obtain the length of time each worker stays in the dangerous area during the spinning process. Through the smart bracelet, the total working time of each worker is obtained, and then the exposure time ratio of each worker in the spinning process is obtained. Through the smart safety helmet, the number of collisions of each worker in the spinning process is obtained, and then the behavioral safety factor of each worker is calculated. The calculation formula is: where χ m represents the behavioral safety factor of the mth worker, a m represents the number of collisions of the mth worker during the spinning process, g m It represents the exposure time proportion of the mth worker in the spinning process.

6. A monitoring system for spinning production according to claim 4, characterized in that: The specific analysis method for evaluating the safety factor of each worker is as follows: Taking the production batch as the statistical unit, the total number of spinning production batches completed within the preset time period is obtained from the database, and the number of safety accidents occurring in the spinning workshop within the preset time period is obtained, and then the safety accident rate of the spinning workshop is calculated. The calculation formula is: Where δ represents the incidence rate of safety accidents in the spinning workshop, f represents the number of safety accidents in the spinning workshop within the preset time period, and f′ represents the total number of spinning production batches completed within the preset time period; Extract the physiological safety factor and behavioral safety factor of each worker, and then evaluate the safety factor of each worker. The calculation formula is: where μ m represents the safety factor of the mth worker, γ1 and γ2 represent the appropriate physiological safety factor weight factor and the appropriate behavioral safety factor weight factor stored in the database, respectively.

7. A monitoring system for spinning production according to claim 1, characterized in that: The specific analysis method for determining the danger level of each worker is as follows: The safety factor of each worker is extracted and compared with the range of worker safety factors corresponding to each hazard level stored in the database. If a worker's safety factor is within the range of worker safety factors corresponding to the low-risk hazard level, the worker's hazard level is determined to be low risk. If a worker's safety factor is within the range of worker safety factors corresponding to the medium-risk hazard level, the worker's hazard level is determined to be medium risk. If a worker's safety factor is within the range of worker safety factors corresponding to the high-risk hazard level, the worker's hazard level is determined to be high risk.

8. A monitoring system for spinning production according to claim 1, characterized in that: The specific analysis method for evaluating the environmental safety factor of the spinning workshop is as follows: Various fire protection measures in the spinning workshop are obtained, and the integrity of fire protection equipment, the effectiveness of fire protection facilities, the rationality of fire protection facility layout, the smooth flow of fire protection passages and the maintenance and management coefficient of fire protection facilities are evaluated, so as to evaluate the environmental safety factor of the spinning workshop. The calculation formula is: F=w1*ρ1+w2*ρ2+w3*ρ3+w4*ρ4+w5*ρ5, where F represents the environmental safety factor of the spinning workshop, w1, w2, w3, w4, and w5 represent the integrity of fire protection equipment, the effectiveness of fire protection facilities, the rationality of fire protection facility layout, the smooth flow of fire protection passages and the maintenance and management coefficient of fire protection facilities in the spinning workshop respectively, and ρ1, ρ2, ρ3, ρ4, and ρ5 represent the appropriate fire protection equipment integrity weight factor, the appropriate fire protection facility functional effectiveness weight factor, the appropriate fire protection facility layout rationality weight factor, the appropriate fire protection passage smoothness weight factor and the appropriate fire protection facility maintenance and management coefficient weight factor stored in the database respectively.

9. A monitoring system for spinning production according to claim 1, characterized in that: The specific analysis method for judging whether the spinning workshop environment is safe is as follows: The environmental safety factor of the spinning workshop is extracted and compared with the threshold value of the environmental safety factor of the spinning workshop stored in the database. If the environmental safety factor of the spinning workshop is lower than the threshold value of the environmental safety factor of the spinning workshop stored in the database, the spinning workshop environment is judged to be unsafe; if the environmental safety factor of the spinning workshop is higher than the threshold value of the environmental safety factor of the spinning workshop stored in the database, the spinning workshop environment is judged to be safe.

10. A method for a monitoring system for spinning production as claimed in any one of claims 1 to 9, characterized in that: include: Step 1: Equipment safety monitoring and management, obtain relevant data of each spinning machine during the spinning process, calculate the operating efficiency and comprehensive energy consumption of each spinning machine, and then determine whether each spinning machine is in normal operating state; Step 2: Manual safety monitoring and management, obtaining relevant data of each worker in the spinning process, calculating the physiological safety factor of each worker, calculating the behavioral safety factor of each worker, and then evaluating the safety factor of each worker and determining the danger level of each worker; Step three, environmental safety monitoring and management, obtain relevant data of the spinning workshop, evaluate the environmental safety factor of the spinning workshop, and then determine whether the spinning workshop environment is safe.

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