A factory equipment monitoring system and monitoring method

Abstract

This invention relates to the field of plant management technology, and more particularly to a plant equipment monitoring system and method, comprising a tracking module, a recording module, an updating module, a monitoring module, and an early warning module. The recording module stores historical call data; the updating module generates standard call information based on historical data after a call is completed; the monitoring module analyzes the difference between the actual call information and the standard call information when a call fails, calculates the deviation value, and feeds back a call reference value to the calling end that failed; the early warning module can issue alarms for abnormal call situations at the calling end. By constructing a multi-module collaborative working mechanism, it can provide quantitative feedback on the current call status when a call fails. Users can analyze the controllability of waiting calls based on the feedback results, enabling real-time dynamic monitoring and refined management of the equipment call process, thereby effectively improving the automation level and scheduling response capability of plant equipment management.

Description

Technical Field

[0001] This invention relates to the field of plant monitoring technology, and in particular to a plant equipment monitoring system and method. Background Art

[0002] In modern factory and warehouse management, equipment dispatch and monitoring, as a crucial link in ensuring efficient production operation, are facing ever-increasing management demands. Traditional equipment monitoring methods mostly rely on manual inspections or simple timed data collection. These methods suffer from insufficient real-time data, limited monitoring scope, and delayed response to anomalies, making them unsuitable for equipment management requirements in high-intensity and complex environments. Currently, some factory equipment monitoring systems primarily focus on static recording of equipment status, failing to fully utilize historical data for in-depth analysis of equipment dispatch patterns to construct standard dispatch paths and durations, and lacking the ability to provide real-time feedback on deviations during actual equipment dispatch. This results in a lack of scientific and timely reference information for managers when equipment dispatch fails or scheduling anomalies occur, reducing the efficiency of equipment resource scheduling and utilization. This has led to the development of digital factory monitoring technologies.

[0003] For example, in the prior art, Chinese Patent Publication No. CN116843497A discloses a multi-dimensional intelligent factory monitoring system based on Internet of Things (IoT) technology, including: a production stage monitoring module, a production output monitoring module, a production management module, a quality monitoring module, an execution terminal, and a database. By acquiring the basic parameters of each production stage corresponding to the current monitoring period for each marked area within the factory area, and analyzing the stage evaluation coefficients of each marked area within the factory area corresponding to the current monitoring period, as well as the output evaluation coefficients of each marked area within the factory area corresponding to the current monitoring period, a comprehensive analysis is conducted to obtain the production management evaluation coefficients of each marked area within the factory area corresponding to the current monitoring period. This avoids the inaccuracies in data caused by manual statistical analysis.

[0004] However, while the above solution has achieved digitalization of factory monitoring, it lacks dynamic analysis of equipment related to the production stage in terms of equipment management in production management. This results in the inability to provide effective technical support when equipment is in short supply, affecting the efficiency of factory operation. Summary of the Invention

[0005] The purpose of this invention is to provide a plant equipment monitoring system and method to solve the problem that the existing technology cannot take into account the dynamic analysis of relevant equipment in the production stage, which leads to the inability to provide effective technical support when equipment is in short supply, thus affecting the plant's operating efficiency.

[0006] To this end, the present invention provides a plant equipment monitoring system, which includes a tracking module, a recording module, an updating module, a monitoring module, and an early warning module. The tracking module is used to obtain the current calling information of each calling terminal. The recording module is connected to the tracking module and is configured to record historical calling information and corresponding calling terminals. The updating module is connected to the recording module and generates at least one standard calling information for the corresponding type of equipment based on the recorded data of the recording module after a single call. The monitoring module is connected to the tracking module, the recording module, and the updating module respectively. The monitoring module is configured to, in response to any calling terminal's call failure, analyze the difference between the calling information of the calling terminal of the corresponding type of equipment that failed the call and the standard calling information to determine the deviation value, and accumulate the deviation values ​​of each calling terminal of the corresponding type of equipment that failed the call as a calling reference value, and feed the calling reference value back to the calling terminal that failed the call. The early warning module is connected to the monitoring module, accumulates and analyzes the deviation values ​​determined by the monitoring module each time, and outputs an abnormal usage alarm in response to the abnormal state of the deviation value.

[0007] The call information includes the call path and the call duration of each node in the call path, and the standard call information includes the standard call path of various types of devices and the standard call duration of each node in the historical call information.

[0008] As a preferred technical solution for a plant equipment monitoring system, the monitoring module is configured to execute the following process to determine the deviation value:

[0009] Based on the current call path obtained by the tracking module, it is matched with the standard call information in the recording module to determine the path similarity between the current call path and the standard call path;

[0010] Calculate the time difference between the call duration of each node in the current call path and the standard call duration. After excluding cases where the time difference is negative, sum the remaining time differences as the time difference degree.

[0011] The deviation value is determined based on the path similarity and the time difference.

[0012] The deviation value is negatively correlated with the path similarity and positively correlated with the time difference.

[0013] As a preferred technical solution for a plant equipment monitoring system, the monitoring module outputs a call reference value to the caller that failed to make a call, and also outputs the current call information of the caller whose call duration is longer than the preset duration and whose deviation value is the lowest.

[0014] As a preferred technical solution for a plant equipment monitoring system, the update module is configured to execute the following process to determine the standard call path;

[0015] The historical call information is categorized based on device type;

[0016] Statistical analysis was performed on the call paths of various types of devices, and the call path with the highest frequency in each type of device was taken as the standard call path for that type of device.

[0017] As a preferred technical solution for a plant equipment monitoring system, the update module is configured to execute the following process to determine the standard call duration of each node in the historical call information;

[0018] Statistical analysis of the duration of each node's calls;

[0019] The average of all call durations is used as the standard call duration for the node.

[0020] As a preferred technical solution for a plant equipment monitoring system, the abnormal states responded by the early warning module include the cumulative deviation value of the calling end exceeding the threshold, and the appearance of a new node in the calling path.

[0021] As a preferred technical solution for the plant equipment monitoring system, the plant equipment monitoring system also includes a level conversion module, which converts the call reference value into multiple levels to represent the waiting level of the caller when the call fails.

[0022] As a preferred technical solution for a plant equipment monitoring system, the plant equipment monitoring system further includes a node partitioning module, which is configured to execute the following process to determine nodes in the call path:

[0023] Location parsing of historical call information;

[0024] Analyze the frequency of equipment dwell time in each plant area, and identify the plant areas where the equipment dwell time is greater than the preset frequency as nodes in the call path.

[0025] As a preferred technical solution for a plant equipment monitoring system, the tracking module specifically includes:

[0026] The data acquisition unit is used to interact with the device to obtain the calling end and the calling duration;

[0027] The positioning unit is used to locate the device position and generate the call path;

[0028] The data transmission unit is used to output the calling terminal, the calling duration, and the calling path to the recording module and the monitoring module, respectively.

[0029] On the other hand, the present invention also provides a plant equipment monitoring method, applied to the plant equipment monitoring system described in any of the above solutions, comprising:

[0030] Obtain and record the call information from the calling end in real time;

[0031] In response to a call failure on any end, determine the call reference value and output it;

[0032] Identify abnormal states of the calling end and output an abnormal call alarm in response to any abnormal state of the calling end.

[0033] The beneficial effects of this invention are as follows:

[0034] The plant equipment monitoring system of the present invention, by constructing a multi-module collaborative working mechanism, can provide quantitative feedback on the current call status when a call fails. Users can analyze the controllability of the waiting call based on the feedback results, and realize real-time dynamic monitoring and refined management of the equipment call process, thereby effectively improving the automation level and scheduling response capability of plant equipment management.

[0035] Furthermore, the tracking module of this invention can improve the timeliness of device management by acquiring real-time call information. When a user fails to call a device, that is, when the same type of device has been called to the point of zero availability, it can provide data support for subsequent feedback as soon as possible.

[0036] Furthermore, the update module of this invention dynamically updates the standard call information, which improves the consistency between the feedback data and the current state while ensuring subsequent data support.

[0037] In particular, when a call fails, the monitoring module of this invention performs a differential analysis on each calling end of the corresponding device type and quantifies it into a deviation value. The higher the deviation value, the more difficult it is to predict and control the calling path and duration of the device. The deviation values ​​of each calling end are accumulated and fed back to the calling end that failed, which can help the calling end analyze the instability of waiting for the call and thus assist the calling end in making a decision. In addition to outputting the calling reference value to the calling end that failed, the monitoring module also outputs the current calling information of the calling end with a calling duration greater than the preset duration and the lowest deviation value. The purpose of this feedback is to provide the user with a calling device that may stop calling in a relatively short period of time and can be stably predicted and controlled to a certain extent. The user can make further decisions based on this feedback result and the calling reference value.

[0038] Furthermore, the early warning mechanism of the early warning module can promptly detect abnormal equipment usage, further enhance the configuration function of the tracking module, and improve the security of plant equipment monitoring. Attached Figure Description

[0039] Figure 1 The structural framework of the plant equipment monitoring system in this embodiment of the invention. Figure 1 ;

[0040] Figure 2 The structural framework of the plant equipment monitoring system in this embodiment of the invention. Figure 2 ;

[0041] Figure 3 This is a structural block diagram of the tracking module in an embodiment of the present invention;

[0042] Figure 4 This is a flowchart of the plant equipment monitoring method in an embodiment of the present invention. Detailed Implementation

[0043] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0044] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0045] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0046] like Figure 1As shown, the present invention provides a plant equipment monitoring system, which includes a tracking module, a recording module, an updating module, a monitoring module, and an early warning module. The tracking module is used to obtain the current calling information of each calling terminal. The recording module is connected to the tracking module and is configured to record historical calling information and corresponding calling terminals. The updating module is connected to the recording module and generates at least one standard calling information for the corresponding type of equipment based on the recorded data of the recording module after a single call. The monitoring module is connected to the tracking module, the recording module, and the updating module respectively. The monitoring module is configured to, in response to any calling terminal's call failure, analyze the difference between the calling information of the calling terminal of the corresponding type of equipment that failed the call and the standard calling information to determine the deviation value, and accumulate the deviation values ​​of each calling terminal of the corresponding type of equipment that failed the call as a calling reference value, and feed the calling reference value back to the calling terminal that failed the call. The early warning module is connected to the monitoring module, accumulates and analyzes the deviation values ​​determined by the monitoring module each time, and outputs an abnormal usage alarm in response to the abnormal state of the deviation value.

[0047] The call information includes the call path and the call duration of each node in the call path. The standard call information includes the standard call path of various types of devices and the standard call duration of each node in the historical call information.

[0048] In the above embodiments, by constructing a multi-module collaborative working mechanism, quantitative feedback on the current call status can be provided when a call fails. Users can analyze the controllability of the waiting call based on the feedback results, enabling real-time dynamic monitoring and refined management of the equipment call process, thereby effectively improving the automation level and scheduling response capability of plant equipment management. Based on the above technical effects, when a call failure occurs, the monitoring module performs a differential analysis on each caller for the corresponding equipment type and quantifies it as a deviation value. The higher the deviation value, the more difficult and uncontrollable the call path and duration of the equipment are to predict. Accumulating the deviation values ​​of each caller and feeding them back as a call reference value to the caller that failed can assist the caller in analyzing the instability of the waiting call, thus aiding the caller in making decisions. Furthermore, while outputting the call reference value to the caller that failed, the monitoring module also outputs the current call information of the caller with a call duration greater than a preset duration and the lowest deviation value. The purpose of this feedback is to provide users with a caller that is likely to stop calling within a relatively short period and is predictably controllable to some extent. Users can then make further decisions based on this feedback and the call reference value.

[0049] Specifically, the monitoring module is configured to execute the following processes to determine deviations:

[0050] Based on the current call path obtained by the tracking module, it is matched with the standard call information in the recording module to determine the path similarity between the current call path and the standard call path;

[0051] Calculate the time difference between the call duration of each node in the current call path and the standard call duration. After excluding cases where the time difference is negative, sum the remaining time differences as the time difference degree.

[0052] The deviation value is determined based on path similarity and time difference.

[0053] Among them, the deviation value is negatively correlated with path similarity and positively correlated with time difference.

[0054] For example, path similarity is the number K1 of identical nodes in the current call path that are the same as those in the standard call path, and the deviation value is determined by:

[0055] Calculate the ratio M of the number of identical nodes K1 to the number of nodes K0 in the standard call path;

[0056] Calculate the ratio N of the time difference T1 to the total call duration T0 of all nodes in the standard call path;

[0057] The difference between N and M, NM, is used as the deviation value. In implementation, the deviation value can also be determined in other ways, as long as the correlation constraint that the deviation value is negatively correlated with path similarity and positively correlated with time difference is met.

[0058] Specifically, while outputting the call reference value to the calling end that failed to make the call, the monitoring module also outputs the current call information of the calling end whose call duration is greater than the preset duration and whose deviation value is the smallest. In detail, the preset duration can be calibrated and configured based on the device type and actual operating conditions. In this embodiment, the preset duration is 50% of the total call duration T0 of all nodes in the standard call path.

[0059] Specifically, the update module is configured to execute the following process to determine the standard call path;

[0060] Historical call information is categorized based on device type;

[0061] Statistical analysis of call paths for various types of devices is performed, and the most frequent call path for each type of device is used as the standard call path. Specifically, the most frequently used call paths are identified by frequency statistics for each device's call paths. The most frequent path often represents the optimal or most common call pattern during normal use, and using it as the standard call path provides an objective and scientific reference for subsequent calculations of call deviation values. Furthermore, this method has the advantages of automation and dynamic adjustment, enabling real-time updates to the standard call path as historical data accumulates, adapting to changes in actual usage. After determining the standard call path, the update module is configured to execute the following process to determine the standard call duration for each node in the historical call information;

[0062] Statistical analysis of the duration of each node's calls;

[0063] The average of all call durations is used as the standard call duration for the node.

[0064] Specifically, the abnormal states detected by the early warning module include the cumulative deviation value of the calling end (i.e., the sum of the deviation values ​​of all calls made by the calling end) exceeding a threshold (the threshold is 1 in this embodiment, but can be adjusted according to actual working conditions), and the appearance of a new node in the call path. In the above embodiment, based on historical data comparison and real-time call behavior analysis, monitoring the cumulative deviation value can effectively identify abnormal usage trends of the calling end and provide early warnings of potential device failures or call strategy deviations. Simultaneously, by detecting new nodes, the system can detect structural changes in the call path, ensuring the controllability and stability of the device call process.

[0065] Please see Figure 2 As shown, the plant equipment monitoring system also includes a level conversion module and a node partitioning module. The level conversion module is connected to the monitoring module, and the node partitioning module is connected to the recording module. The level conversion module converts the call reference value into multiple levels to represent the waiting level of the caller who failed the call. Specifically, the level conversion module receives the call reference value output by the monitoring module and maps the value to multiple preset levels according to the set hierarchical rules. For example, in this embodiment, the call reference value is divided into five levels: Level 1 to Level 5. The mapping of the call reference value to different levels is performed by configuring functions. In this embodiment, a piecewise linear mapping method is used to convert call reference values ​​in different intervals into corresponding call levels. The purpose of level division is to allow the caller who failed the call to quickly understand the difficulty of the call, which is more intuitive than data.

[0066] The node partitioning module is configured to execute the following process to determine nodes in the call path:

[0067] Location parsing of historical call information;

[0068] The frequency of equipment dwell time in each plant area is analyzed, and plant areas with a dwell time greater than a preset frequency (3 times in this embodiment) are identified as nodes in the call path. Historical data reflects the usage frequency of each area during equipment calls, thus accurately identifying key nodes in the call path. Using a preset threshold as the judgment criterion ensures accurate node identification while reducing the risk of misjudgment due to occasional dwell data. It features automation and data-driven characteristics, dynamically updating the node distribution of the call path based on actual usage, providing a precise basis for subsequent standard call information generation and deviation value analysis.

[0069] Please see Figure 3 As shown, the tracking module specifically includes:

[0070] The data acquisition unit is used to interact with the device to obtain the calling end and the calling duration;

[0071] The positioning unit is used to locate the device position and generate the call path;

[0072] The data transmission unit is used to output the calling end, calling duration, and calling path to the recording module and the monitoring module, respectively.

[0073] Please see Figure 4 As shown, this embodiment also provides a method for monitoring plant equipment, including:

[0074] Step S1: Obtain and record the call information from the calling end in real time;

[0075] Step S2: In response to any call failure, determine the call reference value and output it.

[0076] Step S3: Identify the abnormal state of the calling end and output an abnormal call alarm in response to any abnormal state of the calling end. In the above embodiment, by acquiring call information in real time, the timeliness of equipment management can be improved. When a user fails to call a device, that is, when the stock of the same type of device has been called to zero, data support is provided for subsequent feedback as soon as possible. Moreover, the above-mentioned early warning mechanism can promptly detect the abnormal usage status of equipment, further enhance the configuration function of the tracking module, and improve the security of plant equipment monitoring.

[0077] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of apparatus, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, may be implemented using dedicated hardware-based apparatus to perform the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0078] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A plant equipment monitoring system, characterized in that, include: The tracing module is used to obtain the current call information of each calling end; The recording module, connected to the tracking module, is configured to record historical call information and the corresponding calling end; An update module is connected to the recording module. After a single call is completed, the update module generates at least one standard call message for the corresponding type of device based on the recording data of the recording module. The monitoring module is connected to the tracking module, the recording module and the update module respectively. The monitoring module is configured to, in response to any call failure, analyze the difference between the call information of the call terminal of the type of device corresponding to the call failure and the standard call information to determine the deviation value, and accumulate the deviation values ​​of each call terminal of the type of device corresponding to the call failure as the call reference value, and feed the call reference value back to the call terminal that failed. The early warning module is connected to the monitoring module, and accumulates and analyzes the deviation values ​​determined by the monitoring module each time. In response to the abnormal state of the deviation value, it outputs an abnormal usage alarm. The call information includes the call path and the call duration of each node in the call path, and the standard call information includes the standard call path of various types of devices and the standard call duration of each node in the historical call information. While outputting the call reference value to the calling end that failed to call, the monitoring module also outputs the current call information of the calling end whose call duration is greater than the preset duration and whose deviation value is the lowest. The monitoring module is configured to execute the following process to determine the deviation value: Based on the current call path obtained by the tracking module, it is matched with the standard call information in the recording module to determine the path similarity between the current call path and the standard call path; Calculate the time difference between the call duration of each node in the current call path and the standard call duration. After excluding cases where the time difference is negative, sum the remaining time differences as the time difference degree. The deviation value is determined based on the path similarity and the time difference. The deviation value is negatively correlated with the path similarity and positively correlated with the time difference.

2. The plant equipment monitoring system according to claim 1, characterized in that, The update module is configured to execute the following process to determine the standard call path; The historical call information is categorized based on device type; Statistical analysis was performed on the call paths of various types of devices, and the call path with the highest frequency in each type of device was taken as the standard call path for that type of device.

3. The plant equipment monitoring system according to claim 2, characterized in that, The update module is configured to execute the following process to determine the standard call duration of each node in the historical call information; Statistical analysis of the duration of each node's calls; The average of all call durations is used as the standard call duration for the node.

4. The plant equipment monitoring system according to claim 1, characterized in that, The abnormal states responded by the early warning module include the cumulative deviation value of the calling end exceeding the threshold, and the appearance of a new node in the calling path.

5. The plant equipment monitoring system according to claim 1, characterized in that, The plant equipment monitoring system also includes a level conversion module, which converts the call reference value into multiple levels to represent the waiting level of the caller when the call fails.

6. The plant equipment monitoring system according to claim 1, characterized in that, The plant equipment monitoring system also includes a node partitioning module, which is configured to execute the following process to determine nodes in the call path: Location parsing of historical call information; Analyze the frequency of equipment dwell time in each plant area, and identify the plant areas where the equipment dwell time is greater than the preset frequency as nodes in the call path.

7. The plant equipment monitoring system according to claim 1, characterized in that, The tracking module specifically includes: The data acquisition unit is used to interact with the device to obtain the calling end and the calling duration; The positioning unit is used to locate the device position and generate the call path; The data transmission unit is used to output the calling terminal, the calling duration, and the calling path to the recording module and the monitoring module, respectively.

8. A method for monitoring plant equipment, characterized in that, The plant equipment monitoring system according to any one of claims 1-7 includes: Obtain and record the call information from the calling end in real time; In response to a call failure on any end, determine the call reference value and output it; Identify abnormal states of the calling end and output an abnormal call alarm in response to any abnormal state of the calling end.

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