Port hoisting cluster intelligent data acquisition method and terminal

Abstract

The invention discloses an intelligent data acquisition method and terminal for a port crane cluster, and relates to the technical field of data acquisition, and the method comprises the steps: obtaining an output signal of a PLC control system of a port crane; analyzing the output signal, and converting the analyzed signal into a Modbus TCP (Transmission Control Protocol) protocol, so as to obtain converted data; collecting the converted data to obtain first collected data; acquiring key characteristic parameters of an external system with a Modbus TCP interface to obtain second acquisition data; and integrating the first acquisition data and the second acquisition data to obtain the full-parameter data of the port hoisting equipment cluster. According to the data acquisition method based on communication protocol conversion, the problem of data acquisition of different types of PLCs of multiple hoisting equipment in a port is solved.

Description

Technical Field

[0001] This application relates to the technical field of data acquisition, and particularly to an intelligent data acquisition method and terminal for port crane clusters. Background Art

[0002] As a key device for port operations, port cranes undertake the important tasks of cargo loading, unloading and handling, greatly improving the efficiency of cargo handling, reducing labor intensity, and making great contributions to the development of international trade. Modern production operations have put forward higher requirements for port mechanical equipment. Port cranes are developing towards large-scale, high-parameter, and multi-functional directions, and their safe and reliable operation has attracted more and more attention. How to ensure the safety and health of cranes during their service life, discover problems and dispose of them in a timely manner using operating parameters and characteristic data when equipment damage or downtime failures occur, has become a major requirement for ensuring the safe and long-term operation of lifting equipment. Therefore, it is urgent to analyze the operating parameters and characteristic data to realize the operation and maintenance management function driven by dynamic data, provide decision-making basis for the use, maintenance and repair of equipment, and ensure the safe operation of port cranes. Among them, the acquisition of operating parameters and key characteristic data of lifting equipment is a very crucial link.

[0003] Port crane clusters are divided into various types according to their structures, functions and uses, such as bridge cranes (gantry cranes / quayside cranes), gantry cranes (rail-mounted and rubber-tired), and portal cranes. Each crane includes a PLC control system and other external management systems. The operation of the crane is controlled by the PLC control system, including various brands such as Siemens, ABB, Omron, and Schneider, and the data interface protocols provided by them are also different; the external management systems include hydraulic monitoring systems, vibration monitoring systems, etc. The dispersion of each data acquisition system leads to information islands between systems, affecting the integration and utilization of data. It is urgent to build a unified data integration platform through data acquisition. Summary of the Invention

[0004] The purpose of this application is to provide an intelligent data acquisition method and terminal for port crane clusters, which can solve the problem of data acquisition of different types of PLCs of multiple port lifting equipment based on the data acquisition method of communication protocol conversion.

[0005] To achieve the above purpose, this application provides the following solutions.

[0006] In the first aspect, this application provides an intelligent data acquisition method for port crane clusters. The intelligent data acquisition method for port crane clusters includes the following steps.

[0007] Obtain the output signal of the PLC control system of the port crane.

[0008] Parse the output signal and convert the parsed signal into the Modbus TCP protocol to obtain the converted data.

[0009] Collect the converted data to obtain the first collected data.

[0010] Collect the key characteristic parameters of the external system with a Modbus TCP interface to obtain the second collected data.

[0011] Integrate the first collected data and the second collected data to obtain the full-parameter data of the port crane equipment cluster.

[0012] In a second aspect, the present application provides a port crane cluster intelligent data acquisition terminal, which is used to implement the port crane cluster intelligent data acquisition method as described above. The port crane cluster intelligent data acquisition terminal includes the following units.

[0013] An output signal acquisition unit for acquiring the output signal of the port crane PLC control system.

[0014] A protocol conversion unit for parsing the output signal and converting the parsed signal into the Modbus TCP protocol to obtain the converted data.

[0015] A data acquisition unit for collecting the converted data to obtain the first collected data; and also for collecting the key characteristic parameters of the external system with a Modbus TCP interface to obtain the second collected data.

[0016] An integration unit for integrating the first collected data and the second collected data to obtain the full-parameter data of the port crane equipment cluster.

[0017] According to the specific embodiments provided by the present application, the following technical effects are disclosed in the present application.

[0018] The present application provides a method and a terminal for intelligent data acquisition of a port crane cluster. By obtaining the output signals of the PLC control system of the port crane, the operating state of the crane can be understood in real time, providing data support for subsequent diagnostic analysis; parsing the output signals and converting the parsed signals into the Modbus TCP protocol to obtain the converted data, which can convert PLC output signals in different formats into a unified Modbus TCP protocol, facilitating subsequent data processing and transmission; collecting the converted data to obtain the first collected data, which can ensure that all converted data is completely collected, avoid data loss, and can timely reflect the current state of the crane, providing support for real-time monitoring and rapid response; collecting the key characteristic parameters of an external system with a Modbus TCP interface to obtain the second collected data, providing comprehensive characteristic data for the intelligent decision-making system, and supporting more scientific scheduling and management decisions; integrating the first collected data and the second collected data to obtain the full-parameter data of the port crane equipment cluster, which can fuse data from different sources to form a complete data set, providing support for applications such as intelligent monitoring, fault diagnosis, and optimized scheduling, improving the intelligent level of the port. At the same time, through the integrated data, the port equipment can be monitored and managed more effectively, improving the operation efficiency and safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required to be used in the embodiments. Obviously, the drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0020] Figure 1 It is an application environment diagram of a method for intelligent data acquisition of a port crane cluster in an embodiment of the present application.

[0021] Figure 2 It is a schematic flowchart of a method for intelligent data acquisition of a port crane cluster provided in an embodiment of the present application.

[0022] Figure 3 It is a schematic diagram of a parameter list before and after duplicate removal provided in an embodiment of the present application.

[0023] Figure 4 It is a schematic diagram of a parameter list with parameter classification arrangement and new addresses assigned provided in an embodiment of the present application.

[0024] Figure 5 It is a signal flow diagram of a terminal for intelligent data acquisition of a port crane cluster provided in an embodiment of the present application.

[0025] Figure 6 Schematic diagram of the protocol conversion interface provided by an embodiment of the present application.

[0026] Figure 7 Schematic diagram of the data acquisition interface provided by an embodiment of the present application. Detailed implementation manners

[0027] Next, the technical solutions in the embodiments of the present application will be clearly and completely described with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0028] To make the above objects, features, and advantages of the present application more obvious and understandable, the present application will be further described in detail below with reference to the accompanying drawings and specific implementation manners.

[0029] Currently, the operation of most port hoisting equipment is controlled by a PLC system, and the key feature parameter monitoring system is provided by its corresponding supplier. The data is stored in its own system. The data systems are scattered and the data formats are not unified, making it impossible to comprehensively analyze and diagnose the operation data and key feature data of port hoisting machinery. Therefore, the present application proposes a new port hoisting cluster intelligent data acquisition method and terminal.

[0030] The port hoisting cluster intelligent data acquisition method provided by the embodiments of the present application can be applied to, for example Figure 1In the application environment shown. Among them, the terminal 102 communicates with the server 104 through the network. The data storage system can store the data that the server 104 needs to process. The data storage system can be set separately, integrated on the server 104, placed on the cloud or other servers. After the terminal 102 receives the output signal of the port crane PLC control system and the key feature parameters of the external system, the terminal 102 analyzes the output signal, converts the analyzed signal into the Modbus TCP protocol to obtain the converted data; collects the converted data to obtain the first collected data; collects the key feature parameters of the external system with a Modbus TCP interface to obtain the second collected data; integrates the first collected data and the second collected data to obtain the full parameter data of the port crane equipment cluster. The terminal 102 sends the obtained intelligent data of the port crane equipment cluster to the server 104. In addition, in some embodiments, the intelligent data collection method of the port crane cluster can also be implemented by the server 104 alone. For example, the server 104 can obtain the output signal of the port crane PLC control system and the key feature parameters of the external system from the data storage system, and perform data collection on the output signal of the port crane PLC control system and the key feature parameters of the external system.

[0031] Among them, the terminal 102 can be, but is not limited to, an intelligent data collection terminal, or an integration of a data collection module and various desktop computers, laptop computers, tablet computers, etc. The server 104 can be implemented by an independent server or a server cluster composed of multiple servers, and can also be a cloud server.

[0032] In an exemplary embodiment, such as Figure 2 shown, a method for collecting intelligent data of a port crane cluster is provided. This method is executed by an intelligent data collection terminal or a computer device, and can be specifically executed by a computer device such as a terminal or a server alone, or jointly executed by a terminal and a server. In the embodiment of the present application, taking this method applied to Figure 1 the terminal 102 in it as an example for illustration, it includes the following steps S1 to step S5.

[0033] S1: Obtain the output signal of the port crane PLC control system.

[0034] S2: Analyze the output signal and convert it into the Modbus TCP protocol to obtain the converted data.

[0035] S3: Collect the converted data to obtain the first collected data.

[0036] S4: Collect the key feature parameters of the external system with a Modbus TCP interface to obtain the second collected data.

[0037] S5: Integrate the first collected data and the second collected data to obtain the full-parameter data of the port crane equipment cluster.

[0038] Implementing the above steps S1 to S5, in response to the engineering requirement that the data of the port crane cluster is scattered and difficult to analyze and diagnose, this application proposes a port crane cluster intelligent data collection method and terminal. Using a data collection method based on communication protocol conversion to solve the problem of data collection for different types of PLCs of multiple port lifting equipment, a data collection method based on the Modbus TCP protocol is proposed, which supports the access of multiple data sources, realizes the real-time acquisition of equipment operation parameters and key feature data in the PLC control system of the lifting equipment and the external management system, centralizes the management of the data of the scattered system, and provides basic data support for ensuring the safe and healthy operation of the equipment.

[0039] As an optional implementation manner, in step S2, parse the output signal and convert the parsed signal into the Modbus TCP protocol, which specifically includes the following steps.

[0040] S21: Remove duplicates from the PLC parameter list to obtain the first parameter list after duplicate removal; the first parameter list after duplicate removal includes: data name, data type, and data address, as Figure 3 shown.

[0041] S22: After classifying the first parameter list after duplicate removal according to the data type, arrange it in the order of the number of bytes occupied and the address to obtain the first parameter list after classification and arrangement.

[0042] S23: Assign new addresses to the first parameter list after classification and arrangement according to the data type and the number of bytes to obtain the first parameter list with new addresses assigned, as Figure 4 shown.

[0043] S24: Select a driver according to the model of the PLC control system, write the IP address of the PLC output port, and convert the data of the PLC protocol into the Modbus TCP protocol according to the corresponding relationship between the first parameter list after duplicate removal and the first parameter list with new addresses assigned.

[0044] As an optional implementation manner, in step S3, collect the converted data to obtain the first collected data, which specifically includes the following steps.

[0045] S31: Read the data of the converted data according to the Modbus TCP protocol message format to obtain the first data after reading.

[0046] S32: Obtain the starting address and data length of each type of data based on the first parameter list with the new address assigned.

[0047] S33: According to the starting address and data length of each type of data, assign the read first data to the corresponding data type, and correspond one by one with the addresses in the first parameter list with the new address assigned in sequence, to obtain the first acquisition data corresponding to data name - value.

[0048] As an optional implementation manner, in step S4, collect the key feature parameters of the external system with a Modbus TCP interface to obtain the second acquisition data, which specifically includes the following steps.

[0049] S41: Read the data of the key feature parameters of the external system according to the Modbus TCP protocol message format to obtain the read second data.

[0050] S42: Obtain the starting address and data length of each type of data from the second parameter list; the second parameter list includes: data name, data type, and data address.

[0051] S43: According to the starting address and data length of each type of data, assign the read second data to the corresponding data type, and correspond one by one with the addresses in the second parameter list in sequence, to obtain the second acquisition data corresponding to data name - value.

[0052] As an optional implementation manner, the intelligent data acquisition method for the port crane cluster further includes the following steps.

[0053] S6: Display the intelligent data of the port crane equipment cluster in the form of time, data name, and value.

[0054] S7: Obtain the acquisition time and string of the output signal.

[0055] S8: Store the acquisition time and string.

[0056] S9: Obtain the acquisition time and string of the output signal.

[0057] S10: Send the acquisition time and string to the remote platform.

[0058] In summary, in view of the problems of scattered data systems and isolated data in port lifting equipment, the present application proposes a data acquisition method based on communication protocol conversion and the Modbus TCP protocol to obtain the operating parameter data of different types of PLCs and the key feature data of the crane control / monitoring system based on the Modbus TCP protocol, realizing the real-time acquisition of the operating data and key feature data of the lifting equipment, and providing data support for ensuring the safe and healthy operation of the port lifting cluster.

[0059] The present application also provides an application scenario that applies the above-mentioned intelligent data acquisition method for port lifting clusters. Specifically: The intelligent data acquisition method for port lifting clusters provided in this embodiment can be applied in the intelligent data acquisition scenario for port lifting clusters. The intelligent data acquisition scenario for port lifting clusters includes: a data acquisition link, an analysis and conversion link, a data collection link, and an integration link; First, obtain the output signal of the PLC control system of the port crane; Second, analyze the output signal and convert the analyzed signal into the Modbus TCP protocol to obtain the converted data; Then, collect the converted data to obtain the first collected data; Collect the key feature parameters of the external system with a Modbus TCP interface to obtain the second collected data; Finally, integrate the first collected data and the second collected data to obtain the full parameter data of the port lifting equipment cluster.

[0060] Based on the same inventive concept, the embodiment of the present application also provides a port lifting cluster intelligent data acquisition terminal for implementing the above-mentioned intelligent data acquisition method for port lifting clusters. The solution provided by this system to solve the problem is similar to the solution described in the above method. Therefore, the specific limitations in one or more of the following embodiments of the port lifting cluster intelligent data acquisition terminal can refer to the limitations on the intelligent data acquisition method for port lifting clusters in the above text, and will not be repeated here.

[0061] In an exemplary embodiment, as Figure 5 shown, a port lifting cluster intelligent data acquisition terminal is provided, and the port lifting cluster intelligent data acquisition terminal includes the following units.

[0062] An output signal acquisition unit, configured to acquire the output signal of the PLC control system of the port crane.

[0063] A protocol conversion unit, configured to analyze the output signal and convert the analyzed signal into the Modbus TCP protocol to obtain the converted data. The protocol conversion interface is as Figure 6 shown.

[0064] The data acquisition unit is used to acquire the converted data to obtain the first acquired data; it is also used to acquire the key characteristic parameters of an external system with a Modbus TCP interface to obtain the second acquired data. The data acquisition interface is as Figure 7 shown.

[0065] The integration unit is used to integrate the first acquired data and the second acquired data to obtain the full-parameter data of the port crane cluster.

[0066] Specifically, the intelligent data acquisition terminal of the port crane cluster further includes: a signal acquisition and analysis software, a main control unit, a data display unit, a data storage unit, and a data transmission unit.

[0067] The signal acquisition and analysis software is used to send control instructions to the main control unit; it is also used to analyze the acquired data to provide a decision-making basis for the management, use, maintenance, and repair of the equipment.

[0068] The main control unit is used to receive the control instructions and the intelligent data of the port crane cluster, and send the control instructions to the data display unit, the data storage unit, and the data transmission unit.

[0069] The data display unit is used to display the intelligent data of the port crane cluster.

[0070] The data storage unit is used to store the intelligent data of the port crane cluster.

[0071] The data transmission unit is used to send the intelligent data of the port crane cluster to a remote platform.

[0072] The protocol conversion unit analyzes the output signals of common PLC control systems of port cranes (such as SIMATIC, AB, Yaskawa, Omron, etc.) and converts them into the Modbus TCP protocol; the data acquisition unit acquires the data after protocol conversion, and at the same time acquires the key characteristic parameters of an external system with a Modbus TCP interface. With the main control unit as the hardware platform, under the control of the signal acquisition and analysis software, the data display unit and the data storage unit respectively display and store the acquired data, and the data transmission unit sends the acquired data to the remote platform through transmission methods such as wired, enterprise Wifi, or 4G wireless network, so as to realize the real-time online acquisition of the operation parameters and key characteristic parameters of the port lifting equipment.

[0073] The PLC data acquisition method is specifically as follows.

[0074] (1) Data deduplication and key information extraction: Summarize the data of all DB blocks in the PLC. Since the same parameter may be stored in different addresses in the PLC, parameters with the same data name and data type are deduplicated, and only one group is retained to ensure that the same data is collected only once. Each group of data after deduplication should at least include the data name, data type, and data address.

[0075] (2) Data classification and arrangement based on data type: Classify the data processed in step (1) according to the data type, that is, group the data of the same data type together, and then arrange them according to the size of the occupied bytes and the address order.

[0076] (3) PLC-Modbus TCP data mapping: Assign new addresses to the data processed in step (2) according to the data type and the number of bytes. The rule is to accumulate the addresses according to the data type. For example, if the data address of the first BOOL type is 1, the data address of the second BOOL type is 2... the data address of the i-th BOOL type is i, the address of the (i + 1)-th INT type is (i + 1), the address of the (i + 2)-th INT type is (i + 2)... the data address of the (i + n)-th INT type is (i + n), the address of the (i + n + 1)-th REAL type is (i + n + 1), the address of the (i + n + 2)-th REAL type is (i + n + 3)...

[0077] (4) Protocol conversion: Select the driver according to the model of the PLC control system, write the IP address of the PLC output port, import the first parameter list after deduplication and the first parameter list with new addresses, and convert the data of the PLC protocol to the Modbus TCP protocol.

[0078] (5) Modbus TCP protocol data reading: Write the start address and data length of each type of data, import the data list file (including data name, data type, mapping address, etc.), and then read the data according to the Modbus TCP protocol message format.

[0079] (6) Data parsing: According to the type of received data, map the received data to the addresses in the data list file one by one to obtain the data name - value correspondence, and display it in real time.

[0080] (7) Data storage: Store the acquisition time and the string before parsing into a folder, and each folder stores no less than 10,000 groups of data.

[0081] (8) Data sending: Send the acquisition time and the string before parsing. After the remote platform receives the data, it parses the data according to the data type and the data list, and the parsing method is the same as step (6).

[0082] As an alternative implementation, for an external system based on the Modbus TCP protocol, the data acquisition method can be found in steps (5) to (8) of the PLC data acquisition method.

[0083] The intelligent data acquisition terminal for port crane clusters described in this application has the following advantages.

[0084] (1) The protocol conversion unit physically isolates the hoisting machinery PLC control system and the data acquisition unit, avoiding misoperations on the PLC system, minimizing the impact on the normal operation of the crane, and effectively preventing the occurrence of crane safety accidents.

[0085] (2) The protocol conversion function is modularly designed, improving the maintainability of the device.

[0086] (3) The protocol conversion module can add protocol conversion functions for different types of PLCs according to on-site requirements, and has strong scalability.

[0087] The technical features of the above embodiments can be combined arbitrarily. For the sake of brevity of description, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as the scope described in this specification.

[0088] Specific examples are used in this article to elaborate on the principles and implementation methods of this application. The descriptions of the above embodiments are only used to help understand the method and its core idea of this application; at the same time, for those of ordinary skill in the art, according to the idea of this application, there will be changes in the specific implementation methods and application scopes. In summary, the content of this specification should not be construed as a limitation to this application.

Claims

1. A port crane cluster intelligent data collection method, characterized in that: The port crane cluster intelligent data collection method comprises: Obtain the output signal of the port crane PLC control system; Parsing the output signal, and converting the parsed signal into a Modbus TCP protocol to obtain converted data; Collecting the converted data to obtain first collected data; Collecting key characteristic parameters of an external system having a Modbus TCP interface to obtain second collected data; The first collected data and the second collected data are integrated to obtain full parameter data of the port lifting equipment cluster.

2. The port crane cluster intelligent data collection method according to claim 1 is characterized in that: Parsing the output signal and converting the parsed signal into the Modbus TCP protocol specifically includes: Deduplication is performed on the PLC parameter list to obtain a first parameter list after deduplication; the first parameter list after deduplication includes: a data name, a data type, and a data address; After classifying the first parameter list after deduplication according to data types, the first parameter list is arranged according to the number of bytes occupied and the address order to obtain a first parameter list after classification and arrangement; Assigning new addresses to the first parameter list after classification and arrangement according to the data type and the number of bytes to obtain the first parameter list assigned the new addresses; A driver is selected according to the model of the PLC control system, the IP address of the PLC output port is written, and the data of the PLC protocol is converted into the Modbus TCP protocol according to the correspondence between the first parameter list after deduplication and the first parameter list assigned the new address.

3. The port crane cluster intelligent data collection method according to claim 2 is characterized in that: Collecting the converted data to obtain first collected data specifically includes: Reading the converted data according to the Modbus TCP protocol message format to obtain the read first data; Based on the first parameter list assigned to the new address, obtaining the starting address and data length of each type of data; According to the starting address and data length of each type of data, the first data after being read is assigned a corresponding data type, and is matched one by one with the addresses in the first parameter list assigned the new addresses in sequence to obtain the first collected data corresponding to the data name-value.

4. The port crane cluster intelligent data collection method according to claim 1 is characterized in that: The key characteristic parameters of the external system with the ModbusTCP interface are collected to obtain the second collected data, which specifically includes: Reading data of key characteristic parameters of the external system according to the Modbus TCP protocol message format to obtain second data after reading; Obtaining the starting address and data length of each type of data from the second parameter list; the second parameter list includes: data name, data type and data address; According to the starting address and data length of each type of data, the read second data is assigned a corresponding data type, and is matched one-to-one with the addresses in the second parameter list in sequence to obtain the second collected data corresponding to the data name-value.

5. The port crane cluster intelligent data collection method according to claim 1 is characterized in that: The port crane cluster intelligent data collection method also includes: The intelligent data of the port crane cluster is displayed in the form of time, data name and value.

6. The port crane cluster intelligent data collection method according to claim 1 is characterized in that: The port crane cluster intelligent data collection method also includes: Get the acquisition time and character string of the output signal; The acquisition time and character string are stored as data.

7. The port crane cluster intelligent data collection method according to claim 1 is characterized in that: The port crane cluster intelligent data collection method also includes: Get the acquisition time and character string of the output signal; The acquisition time and character string are sent to a remote platform.

8. A port crane cluster intelligent data collection terminal, the port crane cluster intelligent data collection terminal is used to implement the port crane cluster intelligent data collection method according to any one of claims 1 to 7, characterized in that: The port crane cluster intelligent data acquisition terminal includes: An output signal acquisition unit, used to acquire the output signal of the port crane PLC control system; A protocol conversion unit, used for parsing the output signal and converting the parsed signal into a Modbus TCP protocol to obtain converted data; A data acquisition unit, used to acquire the converted data to obtain first acquired data; and also used to acquire key characteristic parameters of an external system having a Modbus TCP interface to obtain second acquired data; The integration unit is used to integrate the first collected data and the second collected data to obtain the port crane equipment cluster intelligent data.

9. The port crane cluster intelligent data acquisition terminal according to claim 8, characterized in that: The port crane cluster intelligent data acquisition terminal also includes: signal acquisition and analysis software, a main control unit, a data display unit, a data storage unit and a data sending unit; The signal acquisition and analysis software is used to send control instructions to the main control unit; it is also used to analyze the collected data to provide a decision-making basis for the management, use, maintenance and repair of the equipment; A main control unit, used for receiving the control instruction and the full parameter data of the port crane equipment cluster, and sending the control instruction to the data storage unit, the data storage unit and the data sending unit; The data display unit is used to display the intelligent data of the port crane cluster; The data storage unit is used to store the intelligent data of the port crane cluster; The data sending unit is used to send the port crane equipment cluster intelligent data to a remote platform.

Images