Real-time monitoring system and method based on communication gateway

Abstract

The invention discloses a real-time monitoring system and method based on a communication gateway, which are applied to an industrial production line, and the system comprises a monitoring module, a communication gateway, a PLC module and an upper computer. The monitoring module is used for collecting multi-dimensional data in a production line in real time; master-slave communication among the communication gateway, the monitoring module and the PLC module is realized through a CAN bus, and the communication gateway is wirelessly connected with an upper computer through the Ethernet, so that multi-dimensional data acquired by the monitoring module in real time is transmitted to the upper computer; the upper computer is used for analyzing the multi-dimensional data and evaluating the working state of the current production line so as to generate a control instruction; and the PLC module is used for receiving a control instruction from an upper computer to realize automatic control of the production line.

Description

Technical Field

[0001] The present invention relates to the field of communication technologies, and in particular, to a real-time monitoring system and method based on a communication gateway. Background Art

[0002] With the continuous progress of computer technologies and information communication technologies, communication has developed from person-to-person communication to person-to-thing and thing-to-thing communication, and tends to transition from local thing-to-thing connection to horizontal cross-application and cross-region Internet of Things. The intelligent communication gateway connects devices or sensors in a small range to the Internet through nodes, realizes protocol conversion between different types of network devices, can not only achieve wide area network interconnection, but also has a device management function, manages relevant information of each node through the network, and realizes remote control. As an important communication device within the network area, different working site conditions will result in different situations.

[0003] The existing industrial production lines generally have the following deficiencies: each functional module operates independently, lacking efficient information transmission and collaboration; the system integration degree is low, resulting in relatively high deployment and maintenance costs for the production line; there is a lack of a real-time data acquisition and feedback mechanism for the production process, resulting in a lack of data support for management decisions and affecting the intelligent level of the production line. Summary of the Invention

[0004] To solve the problems raised in the above background art, the technical solution adopted by the present invention is as follows:

[0005] A real-time monitoring system based on a communication gateway, which is applied to an industrial production line, and includes a monitoring module, a communication gateway, a PLC module, and a host computer;

[0006] The monitoring module is used to collect multi-dimensional data in the production line in real time;

[0007] The communication gateway realizes master-slave communication with the monitoring module and the PLC module through a CAN bus, and the communication gateway is wirelessly connected to the host computer through an Ethernet network, so as to transmit the multi-dimensional data collected by the monitoring module in real time to the host computer;

[0008] The host computer is used to analyze the multi-dimensional data, evaluate the working state of the current production line, and then generate control instructions;

[0009] The PLC module is used to receive control instructions from the host computer and realize automatic control of the production line.

[0010] In some embodiments, the monitoring module includes a camera and multiple types of sensor devices;

[0011] The camera is used to collect video data of the production line, and after the video data collected by the camera is compressed and encoded, it is transmitted to the host computer through the communication gateway;

[0012] The sensor device includes a temperature and humidity sensor for collecting temperature and humidity data of the production line environment, and also includes multiple types of equipment status monitoring sensors for collecting operation data of production equipment in the production line.

[0013] In some embodiments, the host computer adopts a deep learning algorithm model based on the data collected by the monitoring module, and this model is used to automatically identify whether there is an abnormality in the production line.

[0014] In some embodiments, an abnormality early warning module is further included, which is used to achieve instant warning and emergency response when the host computer identifies that there is an abnormality in the production line.

[0015] In some embodiments, the abnormality early warning module includes sound / light alarm devices configured in the factory building; the abnormality early warning module is also configured on the intelligent terminals of the staff.

[0016] On the other hand, the present invention provides a real-time monitoring method based on a communication gateway, which adopts the above-mentioned real-time monitoring system based on a communication gateway, and includes the following steps:

[0017] S1. Real-time collect multi-dimensional data in the production line through the monitoring module;

[0018] S2. Transmit the multi-dimensional data collected by the monitoring module to the host computer through the communication gateway;

[0019] S3. The host computer analyzes the collected multi-dimensional data, evaluates the working state of the current production line, and then generates a control instruction;

[0020] S4. Transmit the control instruction to the PLC module through the communication gateway, and the PLC module automatically adjusts the working state of the production line according to the received control instruction.

[0021] In some embodiments, in step S3, when the host computer analyzes the collected multi-dimensional data, it also identifies whether there is an abnormality in the production line. If so, it transmits the alarm information to the abnormality early warning module through the communication gateway, and the abnormality early warning module realizes instant warning and emergency response after receiving the alarm information.

[0022] In some embodiments, before step S1, multiple evaluation indexes are determined from the multi-dimensional data that can be collected by the monitoring module, and the weight corresponding to each evaluation index is determined according to expert experience. Then, the standard value of each evaluation index is determined, and after normalizing the standard values of all evaluation indexes, an evaluation function is constructed in combination with the corresponding weights;

[0023] In step S3, when the host computer evaluates the working state of the production line, specifically:

[0024] Based on the multi-dimensional data collected in real time, multiple pieces of data selected therefrom as evaluation indicators are called real-time indicator data. After normalizing all the real-time indicator data, they are substituted into a pre-constructed evaluation function. By comparing the differences between the real-time indicator data and the corresponding standard values and performing weighted summation, an evaluation value is calculated, and then the working state of the current production line is evaluated based on the evaluation value.

[0025] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0026] The real-time monitoring method and system based on a communication gateway provided by the present invention monitor different links of a production line through a monitoring module, and transmit the monitoring information to a host computer through the communication gateway. The host computer combines intelligent algorithms to evaluate the working state of the production line. Once the host computer detects an abnormality, an early warning response is automatically realized, which is beneficial to improving production efficiency and flexibility and enhancing the safety control ability of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic flow chart of the intelligent construction site area construction personnel safety work management method provided by the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0028] In order to make the technical means, creative features, achieved purposes and effects of the present invention easy to understand, the present invention will be further described below in conjunction with the drawings and specific embodiments.

[0029] The present invention provides a real-time monitoring system based on a communication gateway, which is applied to an industrial production line and includes a monitoring module, a communication gateway, a PLC module and a host computer;

[0030] The monitoring module is used to collect multi-dimensional data in the production line in real time;

[0031] The communication gateway realizes master-slave communication with the monitoring module and the PLC module through a CAN bus, and the communication gateway is wirelessly connected to the host computer through an Ethernet, so as to transmit the multi-dimensional data collected by the monitoring module in real time to the host computer;

[0032] The host computer is used to analyze the multi-dimensional data, evaluate the working state of the current production line, and then generate control instructions;

[0033] The PLC module is used to receive control instructions from the host computer and realize the automatic control of the production line.

[0034] Preferably, the monitoring module includes a camera and multiple types of sensor devices;

[0035] The camera is used to collect video data of the production line. After the video data collected by the camera is compressed and encoded, it is transmitted to the host computer through the communication gateway;

[0036] The sensor device includes a temperature and humidity sensor for collecting temperature and humidity data of the production line environment, and also includes various device status monitoring sensors for collecting operation data of production equipment in the production line.

[0037] Preferably, based on the data collected by the monitoring module, the host computer adopts a deep learning algorithm model, which is used to automatically identify whether there is an abnormality in the production line.

[0038] Preferably, it further includes an abnormal warning module for realizing instant warning and emergency response when the host computer identifies that there is an abnormality in the production line.

[0039] Preferably, the abnormal warning module includes sound / light alarm devices configured in the factory building; the abnormal warning module is also configured in the intelligent terminals of the staff.

[0040] Refer to Figure 1 As shown, on the other hand, the present invention provides a real-time monitoring method based on a communication gateway, which adopts the above real-time monitoring system based on a communication gateway and includes the following steps:

[0041] S1. Real-time collect multi-dimensional data in the production line through the monitoring module;

[0042] S2. Transmit the multi-dimensional data collected by the monitoring module to the host computer through the communication gateway;

[0043] S3. The host computer analyzes the collected multi-dimensional data, evaluates the working state of the current production line, and then generates a control instruction;

[0044] S4. Transmit the control instruction to the PLC module through the communication gateway, and the PLC module automatically adjusts the working state of the production line according to the received control instruction.

[0045] Preferably, in step S3, when the host computer analyzes the collected multi-dimensional data, it also identifies whether there is an abnormality in the production line. If so, it transmits the alarm information to the abnormal warning module through the communication gateway, and the abnormal warning module realizes instant warning and emergency response after receiving the alarm information.

[0046] Preferably, before step S1, multiple evaluation indicators are determined from the multi-dimensional data that can be collected by the monitoring module, and weights corresponding to each evaluation indicator are determined according to expert experience. Then, the standard value of each evaluation indicator is determined. After normalizing the standard values of all evaluation indicators, an evaluation function is constructed by combining the corresponding weights. The selected evaluation indicators, corresponding weights, and standard values can all be set according to the actual application scenario in combination with expert experience. The evaluation indicators can include various types of data related to safe production collected by multiple types of sensors, such as temperature and humidity data of the production line, operating status data of production equipment, etc.

[0047] In step S3, when the host computer evaluates the working state of the production line, specifically:

[0048] According to the multi-dimensional data collected in real time, multiple pieces of data selected as evaluation indicators are called real-time indicator data. After normalizing all real-time indicator data, they are substituted into the pre-constructed evaluation function. By comparing the differences between the real-time indicator data and the corresponding standard values and performing weighted summation, an evaluation value is calculated, and then the working state of the current production line is evaluated based on the evaluation value.

[0049] In summary, the real-time monitoring method and system based on a communication gateway provided by the present invention monitor different links of the production line through a monitoring module, and transmit the monitoring information to the host computer through the communication gateway. The host computer combines intelligent algorithms to evaluate the working state of the production line. Once the host computer detects an abnormality, an early warning response is automatically realized, which is beneficial to improving production efficiency and flexibility and enhancing the safety control ability of the production line.

[0050] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention, and they should all be covered by the scope of the claims of the present invention.

Claims

1. A real-time monitoring system based on a communication gateway, which is applied to an industrial production line, and is characterized in that, It includes a monitoring module, a communication gateway, a PLC module and a host computer; The monitoring module is used to collect multi-dimensional data in the production line in real time; The communication gateway realizes master-slave communication with the monitoring module and the PLC module through the CAN bus. The communication gateway is wirelessly connected to the host computer through Ethernet, so as to transmit the multi-dimensional data collected by the monitoring module in real time to the host computer; The host computer is used to analyze the multi-dimensional data, evaluate the working state of the current production line, and then generate control instructions; The PLC module is used to receive the control instructions from the host computer and realize the automatic control of the production line.

2. The real-time monitoring system based on a communication gateway according to claim 1, wherein, The monitoring module includes a camera and various types of sensor devices; The camera is used to collect video data of the production line. After the video data collected by the camera is compressed and encoded, it is transmitted to the host computer through the communication gateway; The sensor devices include a temperature and humidity sensor for collecting temperature and humidity data of the production line environment, and also include various types of equipment status monitoring sensors for collecting operation data of production equipment in the production line.

3. The real-time monitoring system based on a communication gateway according to claim 2, characterized in that, Based on the data collected by the monitoring module, the host computer adopts a deep learning algorithm model, which is used to automatically identify whether there is an abnormality in the production line.

4. The real-time monitoring system based on a communication gateway according to claim 3, wherein It further includes an abnormal warning module for realizing instant warning and emergency response when the host computer identifies that there is an abnormality in the production line.

5. The real-time monitoring system based on a communication gateway according to claim 4, wherein The abnormal warning module includes sound / light alarm devices configured in the factory building; the abnormal warning module is also configured on the intelligent terminals of the staff.

6. A real-time monitoring method based on a communication gateway, characterized in that, Adopt the real-time monitoring system based on the communication gateway described in any one of claims 1-5, and include the following steps: S1. Collect multi-dimensional data in the production line in real time through the monitoring module; S2. Transmit the multi-dimensional data collected by the monitoring module to the host computer through the communication gateway; S3. The host computer analyzes the collected multi-dimensional data, evaluates the working state of the current production line, and then generates control instructions; S4. Transmit the control instructions to the PLC module through the communication gateway, and the PLC module automatically adjusts the working state of the production line according to the received control instructions.

7. The real-time monitoring method based on a communication gateway according to claim 6, wherein In step S3, when the host computer analyzes the collected multi-dimensional data, it also identifies whether there is an abnormality in the production line. If so, it transmits the alarm information to the abnormal warning module through the communication gateway, and the abnormal warning module realizes instant warning and emergency response after receiving the alarm information.

8. The real-time monitoring method based on a communication gateway according to claim 7, wherein Before step S1, determine multiple evaluation indexes from the multi-dimensional data that the monitoring module can collect, and determine the weight corresponding to each evaluation index according to expert experience. Then determine the standard value of each evaluation index, and after normalizing the standard values of all evaluation indexes, construct an evaluation function in combination with the corresponding weights; In step S3, when the host computer evaluates the working state of the production line, specifically: According to the multi-dimensional data collected in real time, select multiple data as evaluation indexes from them, which are called real-time index data. After normalizing all real-time index data, substitute them into the pre-constructed evaluation function, and calculate the evaluation value by comparing the difference between the real-time index data and the corresponding standard value and weighted summation, and then evaluate the working state of the current production line according to the evaluation value.

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