Boiler monitoring system based on industrial internet of things

Abstract

The invention belongs to the technical field of boiler monitoring, and discloses a boiler monitoring system and method based on the industrial Internet of Things. The set top box special for the boiler is connected into the detection sensor through a wire, the detection sensor is fixed to the boiler and connected with the monitoring system service center in a wireless / wired mode, and the monitoring system service center is connected with the printer through a wire. The center of the special set top box for the boiler is provided with an MCU, and the MCU is connected with an ETH interface, a CAN interface, a 485 interface, a ModBus interface, an analog quantity interface, a digital quantity interface and a wireless communication module through wires. Various parameters of the boiler are detected through the detection sensor, the set top box special for the boiler collects the parameters through the interface and transmits the parameter data to the system service center in a wireless / wired mode, the structure is simple, compatibility is high, portability is good, and large-area popularization can be achieved.

Description

[0001] This application is a divisional application of the patent application named "A Boiler Monitoring System and Method Based on Industrial Internet of Things". The filing date of the original application is April 13, 2020, and the application number is 202010284544.0. Technical Field

[0002] The present invention belongs to the technical field of boiler monitoring, and particularly relates to a boiler monitoring system and method based on industrial Internet of Things. Background Art

[0003] Currently, the closest prior art: The boiler wireless remote monitoring system uses Internet of Things technology to transmit the real-time operation information of the boiler to the data center platform through wireless data transmission, and the operation status of each boiler can be viewed in real time through the data. If a fault occurs or an alarm is generated, timely processing is carried out.

[0004] There are hundreds of thousands of boilers of various sizes currently in operation in China, which are widely used in industries such as electric power, heating, and bathing. During the use process, due to the negligence of operators, boiler use accidents often occur. Currently, some companies have developed industrial Internet of Things detection terminals, which are composed of an MCU, a bus unit, a wireless data transmission module (single-mode / double-mode optional), an ETH interface, a CAN bus interface, a 485 interface, a digital input / output interface, and an analog input interface. The terminal creatively designs a multi-interface optional mode to adapt to different monitoring scenarios and can accommodate various types of sensors (analog and digital). Currently in China, there are no exactly the same products, and most of the products applied in the market are customized by manufacturers according to actual situations, with poor portability and unable to be widely promoted.

[0005] In summary, the problems existing in the prior art are: Most of the industrial Internet of Things detection terminals applied in the market are customized by manufacturers according to actual situations, with poor portability and unable to be widely promoted.

[0006] The difficulty in solving the above technical problems: How to improve the structure of the industrial Internet of Things detection terminal, enhance portability and practicality, and facilitate wide promotion.

[0007] The significance of solving the above technical problems: Solving the above technical problems can achieve the collection of various parameters of the boiler to the monitoring terminal and transmit them to the background server through wireless / wired means for analysis and processing, which can avoid boiler use accidents, reduce the labor intensity of operators, and improve the safety factor of workers. Summary of the Invention

[0008] In view of the problems existing in the prior art, the present invention provides a boiler monitoring system based on industrial Internet of Things.

[0009] The present invention is implemented as follows. A boiler monitoring system based on the industrial Internet of Things is provided with the following components:

[0010] A dedicated set-top box for boilers;

[0011] The dedicated set-top box for boilers is connected to the detection sensors through wires. The detection sensors are fixed on the boiler and are connected to the monitoring system service center in a wireless / wired manner. The monitoring system service center is connected to a printer through wires;

[0012] The dedicated set-top box for boilers is provided with an MCU at its center. The MCU is connected to an ETH interface, a CAN interface, a 485 interface, a ModBus interface, an analog interface, a digital interface, and a wireless communication module through wires

[0013] The monitoring system service center is provided with a business server and a management console. The business server includes an application module, a service module, a support module, and a platform module; The management console includes an application module; a function module; a platform module

[0014] The application module in the business server includes real-time data collection, device remote control, device distribution monitoring, and statistical charts; The service module includes command control, file service, reports, real-time status processing, real-time event processing, and real-time alarm processing; The support module includes a message queue, a search engine, push, and workflow; The platform module includes an operating system, storage, and network

[0015] The application module in the management console includes configuration and monitoring; The function module includes IoC, AOP, and ORM; The platform module includes JvM and a database.

[0016] In summary, the advantages and positive effects of the present invention are as follows: The present invention detects various parameters of the boiler through detection sensors. The dedicated set-top box for boilers collects the parameters through interfaces and transmits the parameter data to the system service center in a wireless / wired manner. It has a simple structure, strong compatibility, good portability, and can be widely promoted. Brief Description of the Drawings

[0017] Figure 1 is a schematic structural diagram of the boiler monitoring system based on the industrial Internet of Things provided by an embodiment of the present invention;

[0018] Figure 2 is a schematic structural diagram of the dedicated set-top box for boilers provided by an embodiment of the present invention;

[0019] Figure 3 is a schematic structural diagram of the monitoring system service center provided by an embodiment of the present invention;

[0020] Figure 4 is a schematic structural diagram of the typical networking solution of the monitoring system service center provided by an embodiment of the present invention.

[0021] In the figure: 1. Boiler; 2. Detection sensor; 3. Special boiler set-top box; 4. Monitoring system service center; 5. Printer; 6. Wireless communication module; 7. MCU; 8. ETH interface; 9. CAN interface; 10. 485 interface; 11. ModBus interface; 12. Analog quantity interface; 13. Digital quantity interface. Specific implementation

[0022] In order to further understand the content, features and effects of the present invention, the following embodiments are listed and described in detail with the accompanying drawings as follows.

[0023] In view of the problems existing in the prior art, the present invention provides a boiler monitoring system based on industrial Internet of Things. The technical solution of the present invention will be described in detail below with reference to the accompanying drawings.

[0024] Embodiment 1:

[0025] As shown in Figure 1 the figure, the special boiler set-top box 3 is connected to the detection sensor 2 through a wire. The detection sensor 2 is fixed on the boiler 1 and is connected to the monitoring system service center 4 in a wireless / wired manner. The monitoring system service center is connected to the printer 5 through a wire.

[0026] In this embodiment, the boiler 1 has the following functional characteristics:

[0027] High-speed parallel acquisition of 12 channels of analog sensing quantities

[0028] The test range is 4 - 20 mA current-type data;

[0029] The parameter value retains 2 decimal places;

[0030] The analog input and the collector conditioning circuit adopt voltage withstand / current withstand isolation to protect the stability of the subsequent circuit;

[0031] The collected data has a local storage function, allowing the storage of 24-hour data;

[0032] The accuracy reaches industrial level 5;

[0033] High-speed high-voltage parallel 8-channel digital output port

[0034] The digital circuit inputs a 220V AC signal;

[0035] The digital level is 0 / 1;

[0036] 1 channel of collected RS232 communication port, supporting the timely control protocol;

[0037] 1 channel of RS232 communication port for parameter configuration;

[0038] 1-channel RS485 industrial communication bus interface, supporting Modbus protocol and Profibus protocol;

[0039] Support 433Mhz wireless transmission, enabling short-distance data exchange;

[0040] The data transmission channel provides GPRS, supporting dual-server communication function to ensure the reliability of network transmission;

[0041] Data storage SD card, capable of storing up to one day's historical data;

[0042] Multiple status indicator lights;

[0043] Provide an integrated collector server platform and a single-point test tool software.

[0044] Operating temperature range: -30°C to 70°C.

[0045] In this embodiment, the typical networking scheme of the monitoring system service center 4 is as Figure 4 shown and is specifically described as follows:

[0046] Adapter: Obtain data, process and upload it to the system after collation;

[0047] Access server: Receive adapter connections and transfer information between the adapter and the system. The number of supported adapters is in units of "thousands";

[0048] Scheduling and distribution server: Receive data to be processed and schedule it to the appropriate business server for processing according to the load of the business server;

[0049] Real-time business processing cluster: A big data system that provides the ability to analyze and mine historical data;

[0050] Real-time data storage cluster: A big data system that provides the ability to analyze and mine historical data;

[0051] Configuration management server: For use by system administrators to manage configuration parameters and operation permissions.

[0052] The present invention detects various parameters of the boiler 1 through the detection sensor 2, and the boiler-specific set-top box 3 collects the parameters through the interface and transmits the parameter data to the system service center 4 in a wireless / wired manner.

[0053] Embodiment 2:

[0054] As Figure 2As shown in the figure, on the basis of Embodiment 1, an MCU 7 is provided in the center of the special boiler set-top box 3. The MCU 7 is connected to an ETH interface 8, a CAN interface 9, a 485 interface 10, a ModBus interface 11, an analog quantity interface 12, a digital quantity interface 13, and a wireless communication module 6 through wires.

[0055] In this embodiment, the special boiler set-top box 3 can be compatible with different parameter data interfaces such as analog quantities and switch quantities.

[0056] In this embodiment, the design requirements of the special boiler set-top box 3 are as follows:

[0057] It can provide a secure channel. The registration connection verifies the set-top box device number and mobile phone number, and data communication is protected against tampering. It is required to encrypt the data; the configuration software of the acquisition card can configure the acquisition frequency, upload frequency, server IP, port, threshold, etc., and the server can modify the parameters of the sampling card (such as upload frequency, server clock);

[0058] It can give an emergency alarm for data exceeding the threshold; to ensure reliable data transmission,

[0059] The communication with the server adopts an acknowledgment mechanism; a short message channel is reserved, including configuration and active alarm functions;

[0060] The collected data is locally saved for data that has not been successfully sent within one day. When the network is idle (send 60 pieces one by one, and send a group every 29 seconds) or the device is restarted, the data upload and sending are preferentially completed. (The boiler burner has two states: working and standby. When in the standby state, it can be regarded as an idle network period). Standby state: The start signal (in the time control system, the burner status byte is greater than 0) is invalid. Standby state: Send a normal data every 1 minute (fixed), and then send a group of 60 pieces (one by one) of lost packets stored locally every 29s. Abnormal data is sent once every 5s; Working state: Send 60 pieces one by one every 5 minutes, and for the data that has not been sent within less than 5 minutes, store the lost data.

[0061] Transmission method: The UDP / TCP transmission method can be configured through the upper computer software.

[0062] In this embodiment, the special boiler set-top box 3 is configured on-site through a serial port with the upper computer software supporting the terminal before leaving the factory. Configuration parameters: sampling frequency, upload frequency, server IP or domain name, port, UDP / TCP transmission method, threshold, short signal code (owner, 3 numbers can be preset), set-top box number, and GPRS card number.

[0063] In this embodiment, the registration process of the special boiler set-top box 3: After powering on and starting up, it actively sends a data packet to the server. This data packet contains the device number, GPRS card number, and device number of the terminal. After receiving this data, the server replies a data packet to the terminal, which contains: the server synchronization time. The terminal uses this data packet to synchronize the time and determine whether the connection channel is established.

[0064] Registration process: That is, if the connection channel is not established, it sends once every 5s. If it fails 5 times, it restarts the registration process after 1 hour.

[0065] Initial installation / Factory reset: Before successful registration, no data is collected.

[0066] After registering once: After the device restarts, it initiates the registration process again. After all 60 frames of data in each group are lost, the registration process also needs to be restarted, but data needs to be collected at the same time.

[0067] After successful registration, the indicator lights show (red / green). The network indicator light (green single color), the power indicator light (red single color).

[0068] Note: After each power-on, registration is required once.

[0069] In this embodiment, the normal data communication of the special boiler set-top box 3: By default when the device leaves the factory, it collects data once every collection frequency (every 5s), and uploads data item by item (60 items) according to the upload frequency (every 5 minutes). After the server receives each data item, it replies to this data item. For the data that has not received a reply this time, it is stored in the local Flash. Special case: When there is no network service, the 60 data items collected every 5 minutes are stored in the Flash. Only the measurement values of upload failures in one day are stored in the Flash.

[0070] In this embodiment, the alarm data communication of the special boiler set-top box 3: When the data value collected by the set-top box exceeds the set threshold, this data item is immediately uploaded at the next collection frequency (every 5s) and a high priority is set; at the same time, a short message is sent to the owner (only one short message is sent to the owner at the beginning of the entire alarm stage). When the alarm is eliminated, a normal data item is collected and uploaded to inform the server that the alarm status has been eliminated, and a short message is sent to the owner at the same time. (Data conversion within 5 minutes does not alarm) Note: If the alarm value fails to be uploaded successfully, it is treated as upload failure data. When an alarm occurs, if there is still data (less than 60 data items) that has not been uploaded before the alarm moment, the system automatically stores this part of the data in the local Flash and treats it as upload failure data, and the server confirms the alarm data.

[0071] In this embodiment, the processing of upload failure data of the special boiler set-top box 3:

[0072] After the device is restarted, during the initialization process of the previously established channel, all the data in the Flash is uploaded; the upload time interval is 29 seconds. When it conflicts with the standby time interval, the normal data packets during standby are given priority;

[0073] Upload using idle time: Data is collected once every 1 minute during idle time, and the data in the Flash is uploaded every 29 seconds. All data is retransmitted only once during this period.

[0074] In this embodiment, the encryption method of the boiler-specific set-top box 3; the encryption algorithm selects the TEA algorithm. Encryption is only performed on the data field.

[0075] In this embodiment, the data frame format of the boiler-specific set-top box 3:

[0076] 1) Upward general data frame format

[0077]

[0078]

[0079] The starting byte is: 0x55AA

[0080] Version: One byte is user-defined, version 02.

[0081] Data type: Distinguish different frame types, 2 bytes. The upload data type is 0X50XX

[0082] Packet priority:

[0083] 0x00: Working state

[0084] 0x01: Idle state

[0085] 0x02: Alarm state

[0086] Set-top box coding format: Distinguish different boilers.

[0087] Data length: The length N of the data field content.

[0088] Data: Different data types correspond to different data fields.

[0089] Data verification: CRC16 (XMODEM) verification for the received data (except the start, end, and its own verification bytes).

[0090] End byte: 0x7E7F.

[0091] Set-top box coding format (8 bytes)

[0092] Province code (2 bytes): ASCII code (e.g., CQ)

[0093] Serial number (6-digit Arabic numerals):

[0094] Upstream data type field:

[0095]

[0096]

[0097] Downlink general data frame type

[0098]

[0099] The starting byte is: 0x55AA

[0100] Version: One-byte custom, version 02.

[0101] Data type: Distinguish different frame types, 2 bytes. The downlink data type is 0XD0XX.

[0102] Data length: The length N of the data field content.

[0103] Data: Different data types correspond to different data fields.

[0104] Data verification: CRC16 (XMODE) verification for the received data (except the starting, ending, and self-verification bytes).

[0105] Ending byte: 0x7E7F.

[0106] Downlink data type

[0107] Data type Field Remarks Terminal configuration Downlink 0xD001 Registration information Downlink 0xD002 Normal data communication Downlink 0xD003 Alarm data communication Downlink 0xD004 Failed data Downlink 0xD005 Re-registration Downlink 0xD006

[0108] Terminal configuration frame format ----- Data segment

[0109] Online configuration parameters: Server time, upload frequency (range: 1Min - 5Min), sampling frequency, threshold. (If a packet is lost, that is, no confirmation is received from the set-top box, the server-side customizes the retransmission mechanism)

[0110] Downlink configuration data field format: (Data type 0xD001)

[0111]

[0112] Operation instruction:

[0113] 0x00: Indicates that this parameter does not need to be configured

[0114] 0x01: Indicates that this parameter is required.

[0115] Server time:

[0116]

[0117] Upload frequency:

[0118]

[0119] Threshold:

[0120]

[0121]

[0122]

[0123] Uplink configuration data frame field format: (data type 0x5001)

[0124]

[0125] Confirmation configuration:

[0126] 0x00: Indicates that the configuration is unsuccessful

[0127] 0x01: Indicates that the configuration is successful

[0128] Registration information frame format-----Data segment

[0129] Registration process: After the terminal is powered on and starts up, it actively sends a data packet to the server. This data packet contains the device number, GPRS card number, and boiler type of the terminal. After receiving this data, the server sends a data packet back to the terminal, which contains: the server synchronization time. The terminal uses this data packet to synchronize the time and determine whether the channel is established. If the connection channel is not established within the timeout period, it will be resent until the connection is established. After the terminal is reset, it will register again.

[0130] Uplink registration request frame data field format: (data type 0x5002)

[0131]

[0132] Such as: +861359512938700

[0134] Register the set-top box by matching the mobile phone number and set-top box code in a frame of data.

[0135] Downlink confirmation registration request frame data field format: (data type 0xD002)

[0136]

[0137] Normal data communication frame format ----- Data segment

[0138] Normal data communication: By default when the device leaves the factory, the terminal collects data every 5s, packs and uploads 60 pieces of data every 5 minutes. After the server receives each piece of data, it replies to that piece of data. For the data that has not received a reply this time, it will be stored in the local Flash. Special case: When there is no network service, the 60 pieces of data collected every 5 minutes will be stored in the Flash. Only the data with upload failures in one day will be stored in the Flash.

[0139] Uplink normal data communication frame field format: (Data type 0x5003)

[0140] Data field format of one piece of collected data in the boiler data upload frame

[0141]

[0142]

[0143] (Timing control + Collected data) Data field format:

[0144]

[0145]

[0146]

[0147]

[0148]

[0149]

[0150] Note:

[0151] After connecting the timing control, all switch states are subject to the timing control.

[0152] When the timing control device or the set-top box acquisition channel is not connected, all '0' data is sent by default.

[0153] Downlink normal data communication frame field format: (Data type 0xD003)

[0154]

[0155] Alarm data communication frame format ----- Data segment

[0156] Alarm data communication: When the data value collected by the terminal exceeds the set threshold, this piece of data is immediately uploaded at the next 5s and the high priority is set; at the same time, a text message is sent to the owner (only one text message is sent to the owner at the beginning of the entire alarm phase). When the alarm is eliminated, a normal piece of data is collected and uploaded to inform the server that the alarm status has been eliminated, and at the same time, a text message is sent to the owner. Note: If the alarm value fails to be uploaded successfully, it is treated as an upload failure data. When an alarm occurs, if there is still data (less than 60 pieces of data) that has not been uploaded before the alarm time, the system automatically stores this part of the data in the local Flash and treats it as upload failure data.

[0157] Uplink alarm data communication frame field format: (data type 0x5004)

[0158] The data format is the same as the normal communication format, but the sending interval is 5 seconds / each time.

[0159] Downlink confirmation alarm data communication frame data field format: (data type 0xD004)

[0160]

[0161] Upload failure data frame format-----Data segment

[0162] Processing of upload failure data:

[0163] After the device is restarted, during the initialization process of the previously established channel, all the data in the Flash is uploaded;

[0164] Upload using idle time: During idle time, collect and upload the data in the Flash according to the collection in 1 minute.

[0165] Upload failure data frame field format: (data type 0x5005)

[0166] Data field format of a piece of collected data in the boiler data upload frame

[0167]

[0168] Timing control + collected data data field format:

[0169]

[0170]

[0171]

[0172]

[0173] Note: After connecting to the time controller in a timely manner, all switch states shall be subject to the time controller.

[0174] Failure data upload frequency (29 seconds): Each data frame of data.

[0175] The dedicated boiler set-top box 3 provided by the present invention can be connected to multiple different sensors, collect various parameters, and transmit the collected data through the wireless communication module 6.

[0176] Embodiment 3:

[0177] As Figure 3 shown, on the basis of Embodiment 1, the monitoring system service center 4 is provided with a business server and a management console. The business server includes an application module, a service module, a support module, and a platform module; the management console includes an application module; a function module; and a platform module.

[0178] Embodiment 4:

[0179] As Figure 3 shown, on the basis of Embodiment 3, the application module in the business server includes real-time data collection, device remote control, device distribution monitoring, and statistical charts; the service module includes command control, file service, reports, real-time status processing, real-time event processing, and real-time alarm processing; the support module includes a message queue, a search engine, push, and workflow; the platform module includes an operating system, storage, and network.

[0180] Embodiment 5:

[0181] As Figure 3 shown, on the basis of Embodiment 3, the application module in the management console includes configuration and monitoring; the function module includes IoC, AOP, and ORM; the platform module includes JvM and a database.

[0182] When the present invention is in use, first, various parameters of the boiler 1 are detected by the detection sensor 2. The dedicated boiler set-top box 3 collects the parameters through the interface and transmits the parameter data to the system service center 4 in a wireless / wired manner.

[0183] The above are only preferred embodiments of the present invention, and do not impose any form of limitation on the present invention. Any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention are all within the scope of the technical solution of the present invention.

Claims

1. A boiler monitoring system based on the industrial Internet of Things, characterized in that, The boiler monitoring system based on the industrial Internet of Things is provided with: A dedicated set-top box for the boiler; The dedicated set-top box for the boiler is connected to the detection sensor through a wire. The detection sensor is fixed on the boiler and is connected to the monitoring system service center in a wireless / wired manner. The monitoring system service center is connected to the printer through a wire; An MCU is provided in the center of the dedicated set-top box for the boiler. The MCU is connected to an ETH interface, a CAN interface, a 485 interface, a ModBus interface, an analog quantity interface, a digital quantity interface, and a wireless communication module through wires The monitoring system service center is provided with a business server and a management console. The business server includes an application module, a service module, a support module, and a platform module; The management console includes an application module; a function module; the application module in the platform module of the business server includes real-time data acquisition, device remote control, device distribution monitoring, and statistical charts; the service module includes command control, file service, reports, real-time status processing, real-time event processing, and real-time alarm processing; the support module includes a message queue, a search engine, push, and workflow; the platform module includes an operating system, storage, and network The application module in the management console includes configuration and monitoring; the function module includes IoC, AOP, and ORM; the platform module includes JvM and a database.

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