Industrial equipment monitoring system based on wireless communication

Abstract

The embodiment of the invention discloses an industrial equipment monitoring system based on wireless communication. The industrial equipment monitoring system comprises a data acquisition module, a first data forwarding module, a cloud server, a second data forwarding module and a control module, a first wireless communication module is arranged in the first data forwarding module, and the first data forwarding module is configured to transmit the characteristic value data to the cloud server through the first wireless communication module; a second wireless communication module is arranged in the second data forwarding module, and the second data forwarding module is configured to respond to a request data instruction of the control module to obtain the characteristic value data from the cloud server through the second wireless communication module; and the characteristic value data is converted into a standard protocol format and then is transmitted to the control module. According to the embodiment of the invention, the technical effects that wiring-free data transmission is realized and the data can be uploaded to the cloud platform at the same time are achieved.

Description

Technical Field

[0001] This application relates to the field of Internet of Things control technology, and particularly to an industrial equipment monitoring system based on wireless communication. Background Art

[0002] In the fields of industrial automation and the Internet of Things, it is a common method to convert the private protocol data collected by data acquisition devices into industrial standard protocol data to interface with the internal network DCS system or PLC system to achieve industrial equipment monitoring.

[0003] DCS systems and PLC systems usually belong to internal platforms and do not allow access to the external network. Only gateway devices can be deployed within the local area network, and the data of sensors is transparently transmitted to the DCS system or PLC system through the gateway devices. Therefore, on-site gateway wiring and power supply preparation are required, so it is necessary to consider the safety of wiring at the construction site, with high maintenance costs, and the sensor data cannot be uploaded to the cloud platform to achieve online real-time monitoring, and can only be viewed within the local area network. Summary of the Invention

[0004] This application aims to solve at least one of the technical problems existing in the prior art. For this reason, this application proposes an industrial equipment monitoring system based on wireless communication to achieve the technical effect of wire-free data transmission and at the same time the data can be uploaded to the cloud platform.

[0005] This application provides an industrial equipment monitoring system based on wireless communication, including a data acquisition module, a first data forwarding module, a cloud server, a second data forwarding module, and a control module;

[0006] The data acquisition module is configured to collect characteristic value data of the monitored device;

[0007] The first data forwarding module is provided with a first wireless communication module, and the first data forwarding module is configured to transmit the characteristic value data to the cloud server through the first wireless communication module;

[0008] The second data forwarding module is provided with a second wireless communication module, and the second data forwarding module is configured to obtain the characteristic value data from the cloud server through the second wireless communication module in response to a request data instruction of the control module, and convert the characteristic value data into a standard protocol format and then transmit it to the control module.

[0009] In an embodiment of the above industrial equipment monitoring system based on wireless communication,

[0010] The first data forwarding module includes a LoRa gateway, and the LoRa gateway is configured to transmit the characteristic value data to the cloud server or the control module through the first wireless communication module or its serial interface.

[0011] In an embodiment of the above-mentioned industrial equipment monitoring system based on wireless communication,

[0012] The LoRa gateway is configured to establish a TCP connection with the cloud server through the first wireless communication module to transmit data.

[0013] In an embodiment of the above-mentioned industrial equipment monitoring system based on wireless communication,

[0014] The serial interface includes RS232, RS485, CAN, and Ethernet.

[0015] In an embodiment of the above-mentioned industrial equipment monitoring system based on wireless communication,

[0016] The second data forwarding module includes a DTU module;

[0017] The DTU module is configured to communicate with the cloud server in the Modbus-TCP protocol to obtain the characteristic value data; and / or communicate with the control module in the Modbus-RTU protocol to receive the request data instruction or transmit the characteristic value data.

[0018] In an embodiment of the above-mentioned industrial equipment monitoring system based on wireless communication,

[0019] The second data forwarding module includes a local gateway;

[0020] The local gateway is configured to communicate with the cloud server in the HTTP protocol to obtain the characteristic value data; and / or communicate with the control module in the intranet protocol to receive the request data instruction or transmit the characteristic value data.

[0021] In an embodiment of the above-mentioned industrial equipment monitoring system based on wireless communication,

[0022] The data acquisition module is configured to transmit the characteristic value data to the cloud server through the first data forwarding module every first preset time; the control module is configured to obtain the characteristic value data from the cloud server through the second data forwarding module every second preset time.

[0023] In an embodiment of the above-mentioned industrial equipment monitoring system based on wireless communication,

[0024] The first wireless communication module and / or the second wireless communication module is a 4G module, 5G module, or 6G module.

[0025] In an embodiment of the above-mentioned industrial equipment monitoring system based on wireless communication,

[0026] The control module is configured to issue a reminder in a preset form when it receives that at least one of the eigenvalue data appears abnormal.

[0027] In an embodiment of the above industrial equipment monitoring system based on wireless communication,

[0028] The eigenvalue data includes one or more of the sensor ID, timestamp, rotation frequency, three-axis acceleration, three-axis velocity, three-axis displacement, three-axis inclination, surface temperature, sleep time, and battery voltage of the monitored device.

[0029] One or more of the above embodiments of the present application have at least one or more of the following beneficial effects:

[0030] In implementing the technical solution of the present application, through the architecture setting of the industrial equipment monitoring system based on wireless communication, it is realized that the data of the data acquisition module can be uploaded to the online cloud server platform and can also be docked to the control module that cannot access the external network. This application architecture supports the device to collect data and upload it to the wide area network system and the local area network system at the same time; a data forwarding device based on wireless communication is set between the cloud server and the DCS or PLC system to realize data transfer, eliminating the need for wiring, reducing problems such as on-site wiring and power connection of customers, and reducing maintenance costs.

[0031] Additional aspects and advantages of the present application will be given in part in the following description, will become apparent in part from the following description, or will be understood through the practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Referring to the accompanying drawings, the disclosure of the present application will become more understandable. It is easy for those skilled in the art to understand that these drawings are only for illustrative purposes and are not intended to limit the protection scope of the present application. In addition, similar numbers in the figures are used to represent similar components, where:

[0033] Figure 1 is a schematic diagram of the main structure of the industrial equipment monitoring system based on wireless communication in an embodiment of the present application;

[0034] Figure 2 is a schematic diagram of the architecture of the industrial equipment monitoring system based on wireless communication in an embodiment of the present application;

[0035] Figure 3 is a schematic diagram of the architecture of the industrial equipment monitoring system based on wireless communication with a local gateway deployed in an embodiment of the present application. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0036] Some embodiments of the present application will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principle of the present application and are not intended to limit the protection scope of the present application.

[0037] Refer to the attached Figure 1 , Figure 1 is a schematic diagram of the main structure of an industrial equipment monitoring system based on wireless communication according to an embodiment of the present application. As Figure 1 shown, an industrial equipment monitoring system based on wireless communication in an embodiment of the present application mainly includes a data acquisition module, a first data forwarding module, a cloud server, a second data forwarding module, and a control module; the data acquisition module is configured to acquire characteristic value data of the monitored equipment; a first wireless communication module is provided in the first data forwarding module, and the first data forwarding module is configured to transmit the characteristic value data to the cloud server through the first wireless communication module; a second wireless communication module is provided in the second data forwarding module, and the second data forwarding module is configured to obtain the characteristic value data from the cloud server through the second wireless communication module in response to a request data instruction of the control module, and transmit the characteristic value data to the control module after converting it into a standard protocol format. In the present application, the control module can be a DCS or PLC system, which receives the data collected by the sensor, realizes the automatic control and optimization of the industrial process, and improves the production efficiency and safety.

[0038] Specifically, the data acquisition module includes a number of temperature and vibration sensors. One or more temperature and vibration sensors are provided on each monitored equipment. The temperature and vibration sensors collect the characteristic value data on the corresponding monitored equipment and upload it to the cloud server or the control module through the first data forwarding module, cooperate with the system to complete equipment status monitoring and predictive maintenance. The collected characteristic value data includes sensor ID, timestamp, rotation frequency, three-axis acceleration, three-axis velocity, three-axis displacement, three-axis inclination, equipment surface temperature, sleep time, battery voltage, etc. The data is usually private protocol data. The monitored equipment refers to various industrial equipment that needs to monitor its temperature and vibration, such as flue gas fans, etc.

[0039] In one embodiment, the data acquisition module is configured to transmit the characteristic value data to the cloud server through the first data forwarding module every first preset time; the control module is configured to obtain the characteristic value data from the cloud server through the second data forwarding module every second preset time. For example, the temperature and vibration sensors upload the characteristic value data to the cloud server once every hour (the acquisition interval can be adjusted) through the LoRa gateway. As long as there is new data in the cloud server database, it will be updated. The control module (DCS or PLC system) accesses the cloud server through the second data forwarding module (such as DTU) with a wireless communication module at regular intervals (adjustable) to obtain the latest data.

[0040] In one or more embodiments of the present application, through the architecture setting of the industrial equipment monitoring system based on wireless communication, the data of the data acquisition module can be uploaded to the online cloud server platform and docked to the control module that cannot access the external network. This application architecture supports the device to collect data and upload it to the wide area network system and the local area network system at the same time; a data forwarding device based on wireless communication is set between the cloud server and the DCS or PLC system to realize data transfer, which eliminates wiring, reduces problems such as on-site wiring and power connection of customers, and reduces maintenance costs.

[0041] In one embodiment, the first data forwarding module includes a LoRa gateway, which is configured to transmit the eigenvalue data to the cloud server or the control module through the first wireless communication module or its serial interface. Specifically, the LoRa gateway aggregates the data of multiple temperature and vibration sensors and uploads it to the cloud server or the control module through wireless communication or serial interface communication. The LoRa gateway realizes long-distance and low-power data transmission through LoRa technology, which is suitable for remote monitoring in industrial environments.

[0042] In a possible embodiment, the LoRa gateway can establish a TCP connection with the cloud server through the first wireless communication module to transmit data. Specifically, the first wireless communication module is a 4G module, a 5G module or a 6G module; the first wireless communication module uses a 4G, 5G or 6G data card and is inserted into the gateway. Just connect the power supply, and the data can be transmitted through the wide area network to the cloud server, eliminating the gateway wiring. By using LoRa and 4G technologies, efficient and reliable data transmission is achieved.

[0043] In a possible embodiment, the LoRa gateway can communicate with the control module through the serial interface to transmit data. The serial interface includes RS232, RS485, CAN and Ethernet. The data collected by the sensor can be directly transported to the control module through the gateway for the control module to monitor and read.

[0044] In one embodiment, the second data forwarding module includes a DTU module; the DTU module is configured to communicate with the cloud server in the Modbus-TCP protocol to obtain eigenvalue data; and / or communicate with the control module in the Modbus-RTU protocol to receive request data instructions or transmit eigenvalue data, that is, the cloud server and the DTU module communicate in the Modbus-TCP manner to obtain data, and the DTU module communicates the obtained data with the control module through a Modbus-RTU interface (such as an RS485 interface). The DTU module realizes the conversion between serial data (such as RS485) and network data (such as 4G), ensuring the flexibility and reliability of data transmission. It should be understood that in this application, the quantity of each device is arranged according to actual requirements. For example, the DTU module supports 4 communication channels simultaneously and can be configured to work with 4 cloud servers at the same time. The cloud servers coordinate with each other and have a backup mechanism. The illustration is not a limitation on the specific quantity of the devices.

[0045] In a possible embodiment, the second wireless communication module is a 4G module, a 5G module or a 6G module, which supports remote data access and control while eliminating cabling.

[0046] In one embodiment, the control module is configured to issue a reminder in a preset form when at least one eigenvalue data appears abnormal, realizing real-time monitoring of the device status and timely discovering abnormal situations. For example, if a certain device exceeds its threshold, an alarm reminder is issued.

[0047] Based on the above embodiments, refer to Figure 2, A possible working mode of an industrial equipment monitoring system based on wireless communication in this application: The temperature and vibration sensors collect the temperature and vibration data of the equipment in real time. The temperature and vibration data of the private protocol of the monitored equipment collected by the temperature and vibration sensors are transmitted to the LoRa gateway through the sensor hardware LoRa module. The LoRa gateway establishes a long TCP connection with the cloud server. After the LoRa gateway receives the sensor data, it is transparently transmitted to the cloud server through the TCP connection. The cloud server provides data storage, analysis, and visualization functions, supporting remote monitoring and decision-making. Therefore, after the cloud server receives the data transmitted by the LoRa gateway, it performs verification, parsing, and then stores it in the database of the server. After the cloud server verifies that the data is normal, it returns an ACK message to the LoRa gateway. The LoRa gateway transmits the ACK message to the corresponding temperature and vibration sensor. After receiving it, the temperature and vibration sensor enters the sleep instruction or executes other instructions. The cloud server and the 4G DTU communicate in the Modbus-TCP manner to obtain data. The 4G DTU device (DTU module with a 4G card) can implement the function of converting the Modbus TCP protocol into the Modbus RTU protocol, realizing the data conversion of the private protocol. The 4G DTU device communicates with the DCS or PLC system through the Modbus-RTU RS485 interface with the data obtained from the cloud server. The Modbus protocol is in the form of question and answer. In this application, the cloud server acts as a slave station, and the DCS system acts as a master station. Every once in a while, the DCS system actively communicates with the 4G DTU device through the Modbus RTU RS485 interface and sends a command to obtain sensor data. After receiving the request, the 4G DTU device converts the command of the Modbus RTU protocol into the command of the Modbus TCP protocol and sends it to the cloud server. After receiving the Modbus TCP request command of the 4G DTU device, the cloud server parses it, retrieves data from the database as required, transcodes it, and then returns it to the 4G DTU device. After receiving the response data, the 4G DTU device returns it to the DCS system.

[0048] The temperature and vibration sensor data of the private protocol in this application can not only be uploaded to the online cloud server platform but also be docked with the DCS or PLC industrial standard system that cannot access the external network. This set of solutions supports the simultaneous upload of temperature and vibration sensor data to the wide area network system and the local area network system. By supporting multiple communication protocols (such as LoRa, 4G, RS485, Modbus, etc.), the system has good integration capabilities and scalability and can adapt to different industrial environments and requirements. At the same time, a 4G DTU device is added locally between the cloud server and the DCS / PLC system to achieve data transfer. The DTU device has a low cost, a small appearance, and is easy to use. The main thing is that it is free of wiring, reducing the troubles of on-site wiring and power connection for customers.

[0049] In one implementation, refer to Figure 3, the second data forwarding module includes a local gateway; the local gateway is configured to communicate with the cloud server in the HTTP protocol mode to obtain eigenvalue data; and / or, communicate with the control module in the intranet protocol mode to receive request data instructions or transmit eigenvalue data. For example, a local gateway (such as an industrial computer or a dedicated gateway device) is deployed at the customer site. This gateway can access the external network and communicate with the cloud server. The local gateway obtains sensor signals from the cloud server and transmits the data to the control module (DCS or PLC system) through the local network (such as Modbus RTU / TCP, OPC UA, Profibus, etc.); specifically, each temperature and vibration sensor uploads data to the cloud server through a 4G LoRa gateway (a LoRa gateway with a 4G card). The cloud server stores the eigenvalue data and provides data access through the HTTP protocol API interface; the local gateway is deployed in the customer's intranet and can access the external network (cloud server) and the intranet (DCS system). The data receiving service on the local gateway obtains the eigenvalue data from the cloud server through the API. After obtaining the data, the local gateway processes the data (such as format conversion, filtering, etc.). The processed data is sent to the intranet DCS system through the intranet protocol (such as OPC UA, Modbus TCP, MQTT, etc.). The DCS system receives the data from the local gateway and integrates it into the system for processing and display.

[0050] Furthermore, it should be understood that since the settings of each module are only for explaining the functional modules of the device of the present application, the physical devices corresponding to these modules can be the processor itself, or a part of the software in the processor, a part of the hardware, or a part of the combination of software and hardware. Therefore, the number of each module in the figure is only illustrative. Those skilled in the art can understand that the various modules in the system can be adaptively split or combined. Such splitting or combining of specific modules will not cause the technical solution to deviate from the principle of the present application. Therefore, the technical solutions after splitting or combining will all fall within the protection scope of the present application.

[0051] It should be understood that each part of the present application can be implemented by hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, any one or a combination of the following well-known technologies in the art can be used: discrete logic circuits with logic gate circuits for implementing logical functions on data signals, application-specific integrated circuits with suitable combinational logic gate circuits, programmable gate arrays (PGA), field programmable gate arrays (FPGA), etc.

[0052] In the description of this specification, the descriptions referring to terms such as "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples.

[0053] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one of such features. In the description of the present application, the meaning of "a plurality" is at least two, such as two, three, etc., unless otherwise specifically and clearly defined.

[0054] Although the embodiments of the present application have been shown and described above, it can be understood that the above embodiments are exemplary and should not be construed as limiting the present application. Those of ordinary skill in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of the present application.

Claims

1. An industrial equipment monitoring system based on wireless communication, characterized in that, It includes a data acquisition module, a first data forwarding module, a cloud server, a second data forwarding module, and a control module; The data acquisition module is configured to acquire characteristic value data of the device to be monitored; A first wireless communication module is provided in the first data forwarding module, and the first data forwarding module is configured to transmit the characteristic value data to the cloud server through the first wireless communication module; A second wireless communication module is provided in the second data forwarding module, and the second data forwarding module is configured to obtain the characteristic value data from the cloud server through the second wireless communication module in response to a request data instruction of the control module, and convert the characteristic value data into a standard protocol format and then transmit it to the control module.

2. The industrial equipment monitoring system based on wireless communication according to claim 1, wherein The first data forwarding module includes a LoRa gateway, and the LoRa gateway is configured to transmit the characteristic value data to the cloud server or the control module through the first wireless communication module or its serial interface.

3. An industrial equipment monitoring system based on wireless communication according to claim 2, characterized in that, The LoRa gateway is configured to establish a TCP connection with the cloud server through the first wireless communication module to transmit data.

4. An industrial equipment monitoring system based on wireless communication according to claim 2, characterized in that, The serial interface includes RS232, RS485, CAN, and Ethernet.

5. An industrial equipment monitoring system based on wireless communication according to claim 1, characterized in that, The second data forwarding module includes a DTU module; The DTU module is configured to communicate with the cloud server in the Modbus-TCP protocol to obtain the characteristic value data; and / or, communicate with the control module in the Modbus-RTU protocol to receive the request data instruction or transmit the characteristic value data.

6. The industrial equipment monitoring system based on wireless communication according to claim 1, characterized in that, The second data forwarding module includes a local gateway; The local gateway is configured to communicate with the cloud server in the HTTP protocol to obtain the characteristic value data; and / or, communicate with the control module in the intranet protocol to receive the request data instruction or transmit the characteristic value data.

7. An industrial equipment monitoring system based on wireless communication according to claim 1, characterized in that, The data acquisition module is configured to transmit the characteristic value data to the cloud server through the first data forwarding module every first preset time; the control module is configured to obtain the characteristic value data from the cloud server through the second data forwarding module every second preset time.

8. A wireless communication-based industrial equipment monitoring system according to any one of claims 1-7, characterized in that, The first wireless communication module and / or the second wireless communication module is a 4G module, a 5G module, or a 6G module.

9. An industrial equipment monitoring system based on wireless communication according to claim 1, characterized in that, The control module is configured to issue a reminder in a preset form when at least one of the characteristic value data appears abnormal.

10. The industrial equipment monitoring system based on wireless communication according to claim 1, characterized in that, The characteristic value data includes one or more of the sensor ID, timestamp, rotation frequency, three-axis acceleration, three-axis velocity, three-axis displacement, three-axis inclination, surface temperature, sleep time, and battery voltage of the device to be monitored.

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