Crane energy consumption data acquisition device and analysis processing method thereof

Abstract

The invention discloses a crane energy consumption data acquisition device which comprises a network switch and an edge computing platform, the edge computing platform is connected with a PLC (Programmable Logic Controller) control system of harbor machinery in real time through an Ethernet communication interface, and a standard industrial communication protocol Modbus TCP (Transmission Control Protocol) is adopted; and voltage and current data of each electric driver are collected in real time and are used for deploying an energy consumption analysis algorithm. The invention further discloses a crane energy consumption data analyzing and processing method. According to the crane energy consumption data acquisition device and the analysis processing algorithm thereof, high-precision and high-frequency data acquisition can be realized, and real-time data processing can be carried out.

Description

Technical Field

[0001] The present invention relates to the technical field of port machinery and equipment, and more particularly to a crane energy consumption data acquisition device and an analysis and processing method thereof. Background Art

[0002] With the development of global trade, ports, as important hubs for international trade, are facing increasing operational intensity, and the energy consumption of port machinery and equipment is becoming increasingly prominent. Traditional energy consumption monitoring methods rely on manual meter reading or crude meter data collection, which suffers from low data accuracy and poor real-time performance. They cannot meet the needs of precise analysis under dynamic operating conditions and cannot accurately reflect the energy consumption characteristics of electric drive systems during operation. In addition, existing technologies have difficulty in monitoring the real-time power consumption of each drive unit under dynamic operating conditions, which limits the development and implementation of energy-saving measures.

[0003] In recent years, the development of technologies such as the Internet of Things, edge computing, and industrial automation has made high-precision energy consumption monitoring possible. However, existing systems still lack data acquisition frequency, real-time processing capabilities, and integration with existing control systems. Therefore, a high-precision, real-time energy consumption data acquisition device and its analysis and processing algorithm are urgently needed. Summary of the Invention

[0004] The purpose of the present invention is to provide a crane energy consumption data acquisition device and its analysis and processing method, so as to solve the technical problems of traditional energy consumption monitoring systems such as insufficient acquisition accuracy, poor real-time performance, and difficulty in achieving accurate analysis under dynamic working conditions. It can collect data with high precision and high frequency and perform real-time data processing.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] A crane energy consumption data collection device, comprising:

[0007] The communication module uses a network switch that supports standard Ethernet connections. The edge computing platform connects to the port machinery's PLC control system in real time via an Ethernet communication interface. Using the standard industrial communication protocol ModbusTCP, it collects voltage and current data from each electrical drive in real time for deploying energy consumption analysis algorithms.

[0008] Furthermore, the edge computing platform deployed by the algorithm is Jetson Orin Nano (or any edge computing machine with Linux operating system), and the algorithm is developed in Python, including:

[0009] Data acquisition module, which collects electrical drive current and voltage data, as well as equipment operating status signals in real time;

[0010] The data processing module uses a differential algorithm to calculate the instantaneous power and cumulative energy consumption value of each electric drive in real time;

[0011] The data storage and presentation module can display and record the instantaneous power, cumulative energy consumption data of each electric drive, as well as the real-time curve graphs of voltage and current in real time. It can monitor the operation status of the equipment through an intuitive graphical interface, analyze historical data, and detect abnormal situations in a timely manner;

[0012] The PLC control system communication module is connected to the PLC control system of the port machinery through the communication protocol ModbusTCP, and uses the pymodbus library of Python to achieve efficient and reliable data communication;

[0013] The energy feedback judgment module marks the feedback status by comparing the torque and rotational speed directions.

[0014] Furthermore, the Jetson Orin Nano is installed in the equipment electrical control cabinet of the port machinery, and is connected to the PLC control system through an RJ45 Ethernet interface. The data communication link between the Jetson Orin Nano and the PLC control system uses shielded network cable; the Jetson Orin Nano is equipped with an industrial-grade power supply and is provided with heat dissipation and protection facilities.

[0015] Furthermore, the Jetson Orin Nano is provided with an IO interface, and an external button is connected through the IO interface. The Jetson Orin Nano is connected to the touch screen or display terminal supporting the crane energy consumption data acquisition device through HDMI or Ethernet.

[0016] Furthermore, the sampling frequency of the data acquisition module is 100Hz, sampling once every 10ms, and reads the data of the corresponding registers in the PLC control system through ModbusTcpClient to ensure the real-time and accuracy of the acquisition.

[0017] Furthermore, the data processing module conducts data interaction with the PLC control system through the network switch, and obtains the data of the communication between the PLC control system and the electric drive.

[0018] A method for analyzing and processing crane energy consumption data includes the following steps:

[0019] S1. Configure the communication parameters of the crane energy consumption data acquisition device. The communication parameters include the IP address and port number of the PLC control system, as well as the voltage and current register addresses to be collected. The above communication parameters are set through a graphical interface developed by PyQt5 and saved in a configuration file in JSON format;

[0020] S2. The data acquisition module reads the data of the corresponding registers in the PLC control system through ModbusTcpClient at a sampling frequency of once every 10 ms.

[0021] S3. The data processing module is used to calculate the instantaneous power and cumulative energy consumption value of the motor drive in real time. A parallel computing strategy is adopted, and the multi-threading of Python is used to optimize the data processing speed.

[0022] S4. The data storage and presentation module displays and records the instantaneous power, cumulative energy consumption data of each drive unit, as well as the real-time curve graphs of voltage and current in real time, and monitors and records the changes of digital input and output signals.

[0023] S5. The energy feedback judgment module obtains the torque and speed information output from the electric drive to the motor, makes a comparison, and performs energy feedback processing.

[0024] Further, the S3 includes the following steps:

[0025] S31. For a three-phase motor load, the real-time instantaneous power calculation formula is: instantaneous power (W) = voltage (V) × current (A) × 1.732 × power factor.

[0026] Among them, the voltage and current are real-time acquisition data, and the power factor is measured according to the real-time operating state of the electric drive or obtained from the parameter table provided by the electric drive.

[0027] S32. Integrate the instantaneous power at intervals of 10 ms to calculate the cumulative energy consumption value of each electric drive.

[0028] Further, the S5 includes the following steps:

[0029] S51. The energy feedback judgment module makes an energy feedback judgment. When the torque and the motor speed have the same sign, it is in the energy consumption state at this time. When the torque and the speed have opposite signs, it is in the energy feedback state.

[0030] S52. According to the judgment of the energy feedback judgment module, perform energy feedback calculation.

[0031] Adopting the above technical solutions, the present invention has the following advantages:

[0032] The present invention provides a crane energy consumption data acquisition device and its analysis and processing method. By processing data in real time through an edge computing platform, it has low power consumption, few operation problems, a small volume, comprehensive functions, controllable economic costs, eliminates the accuracy loss caused by data transmission delay in traditional systems, and greatly improves the real-time performance and reliability of data analysis. The communication device uses a network switch, communicates based on ModbusTCP, is simply deployed, has high reliability, and is easy to integrate with existing port automation control systems. The sampling frequency reaches 100Hz, which can comprehensively reflect the actual dynamic operation status of the equipment, and realizes high-precision and high-frequency acquisition of energy consumption data of port machinery drive units. In addition, the data storage and presentation module of the crane energy consumption data acquisition device of the present invention can display energy consumption data in real time and perform historical record functions, which is convenient for operators and managers to intuitively analyze the real-time and historical operation status of the equipment, timely discover abnormal energy consumption situations, and assist in formulating energy-saving optimization measures for port machinery. This crane energy consumption data acquisition device has important promotion value and broad application prospects in the field of port machinery energy consumption management and intelligent monitoring. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Other features, objects, and advantages of the present invention will become more apparent by reading the following detailed description of non-limiting embodiments with reference to the accompanying drawings.

[0034] Figure 1 It is the hardware topology diagram of the crane energy consumption data acquisition device of the present invention;

[0035] Figure 2 It is the internal operation flowchart of the software of the crane energy consumption data acquisition device of the present invention;

[0036] Figure 3 It is a screenshot of the main interface of the software system of the present invention:

[0037] Figure 4 It is a screenshot of the software system setting interface of the present invention;

[0038] Figure 5 It is a screenshot after the software successfully connects to the PLC through modbusTCP;

[0039] Figure 6 It is a screenshot of obtaining current and voltage values when the device is running;

[0040] Figure 7 It is a screenshot in the power feeding state when the directions of torque and rotational speed are opposite. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0041] The technical solution of the present invention will be specifically described below in conjunction with the accompanying drawings of the specification. The detailed features and advantages of the present invention are described in detail in the specific implementation manner, and the content is sufficient for any person skilled in the art to understand the technical content of the present invention and implement it accordingly. According to the specification, claims and drawings disclosed in this specification, those skilled in the art can easily understand the related purposes and advantages of the present invention.

[0042] A crane energy consumption data acquisition device with a user-friendly interface is developed based on the Python language and PyQt5, specifically as Figure 1 shown. It communicates with the PLC control system through the Modbus TCP protocol, and real-time obtains the current and voltage values output from the driver of the container lifting equipment to the motor, conducts energy consumption calculation, analysis and recording, and realizes real-time data acquisition, monitoring and evaluation of the energy consumption during the operation of the crane. It includes: a communication module, which uses a network switch and supports standard Ethernet connection; and an edge computing platform (edge device), which is connected to the PLC control system of the port machinery in real time through an Ethernet communication interface, adopts the standard industrial communication protocol Modbus TCP, and real-time collects the voltage and current data of each electric driver for deploying the energy consumption analysis algorithm.

[0043] Among them, the control systems in the current crane electrical rooms are generally equipped with standard Ethernet switches, which can be directly used as network switches. The Modbus TCP protocol (default port 502) is used to exchange data with the PLC control system. The reason for choosing Modbus is that first, it is supported by various brands of PLCs; second, the response speed is relatively fast and suitable for real-time acquisition; third, the configuration is convenient. It supports local network and remote connection modes and adapts to different application scenarios. As long as there is network access, the edge computing platform can be installed anywhere, it can be installed near the electrical room, or in the driver's cab. If it is considered that the hardware status can be detected and maintained in real time, it can also be placed in the central control room. The Modbus communication adopts a client-server architecture, with the edge computing device as the Modbus TCP client and the PLC control system as the Modbus TCP server. Based on the Modbus TCP communication, the deployment is simple, the reliability is high, and it is easy to integrate with the existing port automation control system. By processing data in real time through the edge computing platform, the accuracy loss caused by the data transmission delay of the traditional system is eliminated, and the real-time performance and reliability of data analysis are greatly improved.

[0044] The data source in the present invention obtains the output value of the motor driver by communicating between the PLC control system of the crane and the motor driver. The acquisition frequency of the motor driver collected by the PLC control system is 20 ms, and the edge computing platform exchanges data with the PLC through an Ethernet switch to obtain data. The data source is the processed motor driver data in the PLC control system.

[0045] In a specific embodiment, the hardware deployment of the edge computing platform uses Jetson Orin Nano as the core computing platform. Jetson Orin Nano has high-performance GPU acceleration and powerful edge computing capabilities, and can meet the requirements of high-frequency data collection and real-time data processing. The deployment plan includes: installing Jetson Orin Nano in the electrical control cabinet of port machinery equipment, connecting it to the PLC control system of the equipment through an RJ45 Ethernet interface, and establishing a stable and reliable ModbusTCP communication. Jetson Orin Nano has low power consumption and is powered by an industrial-grade power module to ensure the stability and reliability of long-term operation, and is equipped with necessary heat dissipation and protection facilities. According to the actual situation on site, the data communication link between Jetson Orin Nano and the PLC control system needs to use shielded network cables to avoid the impact of on-site electromagnetic interference on communication quality.

[0046] The touch screen or display terminal supporting the crane energy consumption data acquisition device is installed in the operation room and connected to Jetson Orin Nano through HDMI or Ethernet to provide a local real-time data monitoring and interaction interface. In addition, as an edge computing platform, Jetson Orin Nano has an extremely low power consumption of 15W and has an IO interface function. The functions of button start, reset, and snapshot software are realized by externally connecting buttons through the IO interface.

[0047] Among them, Jetson Orin Nano includes: a data acquisition module that real-time collects the current and voltage data of the electrical drive and the equipment operation status signal; a data processing module that uses a differential algorithm to real-time calculate the instantaneous power and cumulative energy consumption value of each electrical drive; a data storage and presentation module that can real-time display and record the instantaneous power, cumulative energy consumption data of each electrical drive, and the real-time curve graph of voltage and current, and real-time monitor the equipment operation status through an intuitive graphical interface, analyze historical data, and timely discover abnormal situations; a PLC control system communication module that is connected to the PLC control system of the port machinery through the communication protocol ModbusTCP, and uses the pymodbus library to achieve efficient and reliable data communication; an energy feedback judgment module that marks the feedback status by comparing the torque and rotation speed directions. In addition, the sampling frequency of the data acquisition module is 100Hz, sampling once every 10ms, and reading the data of the corresponding register in the PLC control system through ModbusTcpClient to ensure the real-time and accuracy of the acquisition. The data processing module conducts data interaction with the PLC control system through a network switch to obtain the data of the communication between the PLC control system and the electrical drive.

[0048] A method for analyzing and processing crane energy consumption data includes the following steps:

[0049] S1. Configure the communication parameters of the crane energy consumption data acquisition device. The communication parameters include the IP address and port number of the PLC control system, as well as the voltage and current register addresses to be collected. The above communication parameters are set through a graphical interface developed by PyQt5 and saved in a configuration file in JSON format.

[0050] The internal operation flowchart of the software of the crane energy consumption data acquisition device is specifically as Figure 2 shown. First, the system is initialized to establish a connection with the PLC control system, and then data acquisition loop, energy consumption calculation loop, and data recording loop are carried out. Finally, user interaction response is performed.

[0051] After the software is run for the first time, it is necessary to set the IP address and server port of the ModbusTCP server and save them as a configuration file in a.json format. Every time it is run later, it will default to automatically load the connection parameters such as the IP address and port number of the PLC control system from the configuration file. Then create an instance of ModbusTcpClient to establish a connection with the PLC control system (that is, ModbusTCP Server). Verify the connection status to ensure that the communication link is unobstructed. The parameter acquisition method adopts a multi-threaded parallel reading mechanism to improve the data acquisition efficiency. Set the corresponding register address mapping relationship for different device components. Optimize the concurrent reading performance through a thread pool to reduce the impact of network latency.

[0052] S2. The data acquisition module reads the data of the corresponding registers in the PLC control system through ModbusTcpClient at a sampling frequency of once every 10 ms. Adopt a multi-threaded parallel reading mechanism to improve the data acquisition efficiency. Set the corresponding register address mapping relationship for different device components. Optimize the concurrent reading performance through a thread pool to reduce the impact of network latency, and the data reading frequency can reach the millisecond level at most to ensure real-time performance.

[0053] Data Type and Source

[0054] Analog data:

[0055] (1) Current value: Output current of each driver

[0056] (2) Voltage value: Output voltage of each driver

[0057] (3) Register type: Holding Registers

[0058] Digital data:

[0059] (1) Equipment operation status: Auxiliary equipment such as brakes, lighting, and air conditioners

[0060] (2) Current direction judgment signal: used to determine the energy flow direction

[0061] (3) Register type: Discrete Inputs

[0062] The following is the Modbus TCP interface table with the PLC:

[0063] Request from client to server (register): 00 01 00 00 00 06 01 03 00 00 00 18

[0065] Analysis:

[0066] Transaction ID: 0x0001

[0067] Protocol ID: 0x0000

[0068] Length: 0x0006 (6 bytes)

[0069] Unit ID: 0x01

[0070] Function code: 0x03 (Read holding register)

[0071] Starting address: 0x0000 (register 0)

[0072] Number of registers: 0x0018 (24 registers)

[0073] Response from server (register):

[0074] 00 01 00 00 00 31 01 03 30xx xx xx xx xx xx xx xx xx xx xx xx xx xxxx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx xxxx xx xx xx

[0075] Analysis:

[0076] Transaction ID: 0x0001

[0077] Protocol ID: 0x0000

[0078] Length: 0x0031 (49 bytes)

[0079] Unit ID: 0x01

[0080] Function code: 0x03

[0081] Number of bytes: 0x30 (48 bytes)

[0082] Register values (24 registers, 2 bytes each): For example, 0x0064 occupies xx xx, representing 100 in decimal. This changes according to the mapped values. There should be 24 values in total (24 xxxx)

[0083]

[0084]

[0085] Client-to-server request (discrete input): 00 02 00 00 00 06 01 02 00 00 00 16 Analysis:

[0086] Transaction ID: 0x0002

[0087] Protocol ID: 0x0000

[0088] Length: 0x0006 (6 bytes)

[0089] Unit ID: 0x01

[0090] Function code: 0x02 (read discrete input)

[0091] Starting address: 0x0000 (discrete input 0)

[0092] Number of input points: 0x0016 (22 points)

[0093] Server response (discrete input): 00 02 00 00 00 06 01 02 03xx xx xx Analysis:

[0094] Transaction ID: 0x0002

[0095] Protocol ID: 0x0000

[0096] Length: 0x0006 (6 bytes)

[0097] Unit ID: 0x01

[0098] Function code: 0x02

[0099] Number of bytes: 0x03 (3 bytes)

[0100] Input status (3 bytes):

[0101] First group xx: 0xA5 (representing binary: 10100101, 0 and 1 represent the state of a certain switch quantity), 8 switch quantities per group, 3 groups of 24 switch quantities.

[0102] Modbus Address|Internal Address|Data Type|Number of Bytes|Description

[0103] 10001|0|BOOL|1bit|Signal to turn on the floodlight (contactor signal is 1 for on and 0 for off)

[0104] 10002|1|BOOL|1bit|Signal to turn on the step light (contactor signal is 1 for on and 0 for off)

[0105] 10003|2|BOOL|1bit|Signal to turn on the air conditioner (contactor signal is 1 for on and 0 for off)

[0106] 10004|3|BOOL|1bit|Signal to turn on the hoist brake (contactor signal is 1 for on and 0 for off)

[0107] 10005|4|BOOL|1bit|Signal to turn on the trolley brake (contactor signal is 1 for on and 0 for off)

[0108] 10006|5|BOOL|1bit|Signal to turn on the gantry brake (contactor signal is 1 for on and 0 for off)

[0109] 10007|6|BOOL|1bit|Signal to turn on the micro-motion brake (contactor signal is 1 for on and 0 for off)

[0110] 10008|7|BOOL|1bit|Signal for the reel to run (contactor signal is 1 for on and 0 for off)

[0111] 10009|8|BOOL|1bit|Signal for the steering push rod 1 to rotate forward (contactor signal is 1 for on and 0 for off)

[0112] 10010|9|BOOL|1bit|Signal for the steering push rod 2 to rotate forward (contactor signal is 1 for on and 0 for off)

[0113] 10011|10|BOOL|1bit|Signal for the steering push rod 3 to rotate forward (contactor signal is 1 for on and 0 for off)

[0114] 10012|11|BOOL|1bit|Signal for the steering push rod 4 to rotate forward (contactor signal is 1 for on and 0 for off)

[0115] 10013|12|BOOL|1bit|Signal for the heater to run (contactor signal is 1 for on and 0 for off)

[0116] 10014|13|BOOL|1bit|Signal for the spreader to extend and retract (contactor signal is 1 for on and 0 for off)

[0117] 10015|14|BOOL|1bit|Comparison of the direction of the hoisting torque and speed (1 for the same direction, 0 for the opposite direction). A logic block needs to be created in the PLC to compare the signs of the torque and speed. If the signs are the same, it is 1; otherwise, it is 0

[0118] 10016|15|BOOL|1bit|Comparison of the direction of the trolley torque and speed (1 for the same direction, 0 for the opposite direction). A logic block needs to be created in the PLC to compare the signs of the torque and speed. If the signs are the same, it is 1; otherwise, it is 0

[0119] 10017|16|BOOL|1bit|Comparison of the direction of the trolley torque and speed (1 for the same direction, 0 for the opposite direction). A logic block needs to be created in the PLC to compare the signs of the torque and speed. If the signs are the same, it is 1; otherwise, it is 0

[0120] 10018|17|BOOL|1bit|Comparison of the direction of the fine movement #1#3 torque and speed (1 for the same direction, 0 for the opposite direction). A logic block needs to be created in the PLC to compare the signs of the torque and speed. If the signs are the same, it is 1; otherwise, it is 0 F

[0121] 10019|18|BOOL|1bit|Comparison of the direction of the fine movement #1#4 torque and speed (1 for the same direction, 0 for the opposite direction). A logic block needs to be created in the PLC to compare the signs of the torque and speed. If the signs are the same, it is 1; otherwise, it is 0

[0122] 10020|19|BOOL|1bit|Unlock command (1 for giving the command, 0 for the normal state)

[0123] 10021|20|BOOL|1bit|Lock command (1 for giving the command, 0 for the normal state)

[0124] 10022|21|BOOL|1bit|Other running signal #8 (1 for positive arbitrarily, 0 for negative)

[0125] Address conversion in actual communication

[0126] In actual Modbus communication, these addresses will be converted to indexes starting from 0:

[0127] Address 10001 corresponds to index 0 (discrete input), so it is 10001 - 10023

[0128] Address 40001 corresponds to index 0 (holding register), so it is 40001 - 40025

[0129] The register stores current and voltage data, and the numerical value needs to be changed to the actual 16 - bit data.

[0130] S3. Use the data processing module to calculate the instantaneous power and cumulative energy consumption value of the motor drive in real time. Adopt a parallel computing strategy and use the multi-threading of Python to optimize the data processing speed;

[0131] S3 includes the following steps:

[0132] S31. For a three-phase motor load, the real-time instantaneous power calculation formula is: Instantaneous power (W) = Voltage (V) × Current (A) × 1.732 × Power factor,

[0133] where the voltage and current are real-time collected data, and the power factor is measured according to the real-time operating state of the electric drive or obtained from the parameter table provided by the electric drive;

[0134] S32. Integrate the instantaneous power at intervals of 10 ms to calculate the cumulative energy consumption value of each electric drive unit, ensuring the accuracy and real-time performance of the calculation results.

[0135] In a specific embodiment, the energy consumption calculation method is as follows:

[0136] Power calculation: For the main drive system (hoisting, trolley, gantry, fine motion, configured according to the actual equipment situation):

[0137] (1) Power (kW) = Current (A) × Voltage (V) × 1.732 / 1000

[0138] (2) The formula is relatively simple because the data obtained is the actual data output from the drive to the motor, not the theoretical data.

[0139] (3) Among them, 1.732 is in a three-phase system, and the phase difference between each phase voltage is 120 degrees. Therefore, the line voltage is

[0140] For auxiliary equipment (lighting, brakes, air conditioners, etc.):

[0141] (1) Power (kW) = Equipment rated power (W) × Operating state (0 or 1) / 1000

[0142] Energy consumption integration: Calculate the energy consumption increment based on the time interval:

[0143] (1) Time difference (hours) = (Current time - Last calculation time) / 3600000

[0144] (2) Energy consumption increment (kWh) = Power (kW) × Time difference (hours)

[0145] Cumulative energy consumption value:

[0146] (1) Current cumulative energy consumption = Original cumulative energy consumption + Energy consumption increment.

[0147] S4. The data storage and presentation module displays and records in real time the instantaneous power, cumulative energy consumption data of each drive unit, as well as the real-time curve graphs of voltage and current, monitors and records the changes of digital input and output signals; users can monitor the operation status of the device in real time through an intuitive graphical interface, analyze historical data, and detect abnormal situations in a timely manner. It can monitor and record the changes of digital input and output signals, such as the operation status of auxiliary devices such as brakes, lighting, and air conditioners, for operation status diagnosis and fault analysis. In this way, the efficiency of equipment maintenance and safety management is further improved.

[0148] In the graphical interface, the functions of the main interface are specifically as Figure 3 shown, and the functions are as follows:

[0149] (1) Display the current and voltage values of each driver in real time; (2) Display the cumulative energy consumption and energy feedback of each system; (3) Intuitively display the numerical size using a progress bar; (4) Automatically adjust the color according to the numerical range.

[0150] The settings interface is specifically as Figure 4 shown, and the functions are as follows: (1) Configuration of server connection parameters; (2) Setting of register address mapping; (3) Configuration of device power parameters; (4) Selection of system operation mode.

[0151] The status indication is specifically as Figure 5 and Figure 6 shown. (1) Dynamic display of connection status: The dynamic display after the software successfully connects to the PLC through modbusTCP is specifically as Figure 5 shown.

[0152] (2) Indication of device operation status: When the device starts to have output and runs, read the modbusTCP register address to obtain the current and voltage values of each mechanism, and the operation status indication is specifically as Figure 6 shown.

[0153] S5. Through multiple actual measurements and on-board waveform observations, the current and voltage of the electric drive have no positive or negative directions, so the feedback energy cannot be directly counted. However, by observing that the torque output from the electric drive to the motor and the motor speed have positive and negative distinctions, the energy feedback judgment module obtains the torque and speed information output from the electric drive to the motor, makes a comparison, and performs energy feedback processing. The relationship between them can be used to judge whether the electric energy is in a power-consuming state or an energy feedback state. When the torque and the motor speed have the same sign, it is in an energy-consuming state at this time. When the torque and the speed have opposite signs, it is in an energy feedback state.

[0154] Therefore, in order to process the statistics of the feedback energy more conveniently and efficiently, a logical judgment is made in the PLC program, and after the judgment, a BOOL quantity is used to give the energy consumption system to judge whether the energy consumption calculation should be carried out in the positive or negative direction of the current at this time.

[0155] S5 specifically includes the following steps:

[0156] S51. The energy feedback judgment module makes an energy feedback judgment. When the torque and the motor speed have the same sign, it is in the energy consumption state at this time. When the torque and the speed have opposite signs, it is in the energy feedback state, and the motor is in the power generation state at this time, specifically as Figure 7 shown.

[0157] S52. According to the judgment of the energy feedback judgment module, the energy feedback calculation is carried out. When the current and voltage are negative values, the power is included in the energy feedback cumulative value of the corresponding system.

[0158] Current direction judgment:

[0159] (1) By reading the dedicated discrete input signals (10015 - 10019) provided by the PLC

[0160] (2) When the signal is False, it means that the current is negative (energy feedback)

[0161] Energy feedback calculation:

[0162] (1) When the current is negative, the power is included in the energy feedback cumulative value of the corresponding system

[0163] (2) Support for configuring whether to enable the energy feedback function (some devices use power supplies such as diesel engines and do not have the function of energy feedback to the power grid. Excess braking energy and potential energy are all burned with braking resistors)

[0164] The data storage and management in the present invention are as follows:

[0165] 1) Data recording method

[0166] Energy consumption data recording: [[ID=--]]

[0167] (1) File format: JSON structured data.

[0168] (2) Recording frequency: Can be configured and modified (default every 10 seconds).

[0169] (3) File naming: Automatically generated based on the device number. Considering that multiple edge devices can be installed distributively on various devices in the dock, the energy consumption data can be summarized through the network to the central control wall-mounted software for data display.

[0170] Operation log recording:

[0171] (1) File format: CSV tabular data. CSV is used here to avoid confusion with energy consumption data.

[0172] (2) Record content: Operation time, operation type.

[0173] (3) Automatically create files and headers.

[0174] 2) Data structure design

[0175] Energy consumption data structure:

[0176]

[0177]

[0178] The system configuration and expansion in the present invention are as follows:

[0179] 1) Configuration file management

[0180] Use JSON format to store configurations:

[0181] (1) Server connection parameters.

[0182] (2) Register address mapping.

[0183] (3) Equipment power parameters, energy consumption statistics of auxiliary components. Since only their states can be known, they can only be preset.

[0184] (4) System operation options.

[0185] Configuration interface support:

[0186] (1) Load existing configurations.

[0187] (2) Modify configuration parameters.

[0188] (3) Save new configurations.

[0189] (4) Clear configurations.

[0190] 2) System expansion ability

[0191] Modular design, supporting function expansion:

[0192] (1) New device types can be added, and data signals can be increased through signals from other sensors or direct IO input.

[0193] (2) Data analysis functions can be expanded, and data comparison can be performed on the saved data according to time series or device operation status to find energy consumption optimization solutions.

[0194] (3) The remote monitoring ability can be enhanced to transmit data to the central control through the network for dynamic display of energy consumption data.

[0195] Reserved interfaces for easy integration:

[0196] (1) Data export interface.

[0197] (2) Third-party system integration interface.

[0198] (3) Alarm and notification mechanism.

[0199] The internal operation process of the energy consumption software in the present invention is as follows:

[0200] System initialization:

[0201] (1) Load configuration file

[0202] (2) Initialize data structure

[0203] (3) Prepare user interface

[0204] Establish PLC connection:

[0205] (1) Verify IP address and port

[0206] (2) Create Modbus client

[0207] (3) Confirm connection status

[0208] Data acquisition loop:

[0209] (1) Read register values (current, voltage)

[0210] (2) Read discrete inputs (device status)

[0211] (3) Process raw data

[0212] Energy consumption calculation loop:

[0213] (1) Calculate power of each system

[0214] (2) Judge energy flow direction

[0215] (3) Accumulate energy consumption and feedback

[0216] Data recording loop:

[0217] (1) Regularly save energy consumption data

[0218] (2) Record operation events

[0219] (3) Manage historical data

[0220] User interaction response:

[0221] (1) Processing parameter setting

[0222] (2) Response control command

[0223] (3) Update interface display

[0224] Finally, it should be noted that although the present invention has been described with reference to the current specific embodiments, those of ordinary skill in the art should recognize that the above embodiments are only used to illustrate the present invention and are not intended to limit the present invention. Various equivalent changes or substitutions can be made without departing from the concept of the present invention. Therefore, as long as the changes and modifications to the above embodiments are within the scope of the spirit of the present invention, they will fall within the scope of the claims of the present invention.

Claims

1. A crane energy consumption data acquisition device, characterized in that Including: A communication module, using a network switch, supporting standard Ethernet connections; And An edge computing platform, which is connected to the PLC control system of port machinery in real time through an Ethernet communication interface, adopts the standard industrial communication protocol ModbusTCP, and collects the voltage and current data of each electric drive in real time for deploying an energy consumption analysis algorithm.

2. The energy consumption data acquisition device of a crane according to claim 1, characterized in that The edge computing platform is Jetson Orin Nano, including: A data acquisition module, which collects the current and voltage data of the electric drive and the equipment operation status signal in real time; A data processing module, which uses a differential algorithm to calculate the instantaneous power and cumulative energy consumption value of each electric drive in real time; A data storage and presentation module, which can display and record the instantaneous power, cumulative energy consumption data of each electric drive, and the real-time curve graphs of voltage and current in real time, monitor the equipment operation status in real time through an intuitive graphical interface, analyze historical data, and detect abnormal situations in time; A PLC control system communication module, which is connected to the PLC control system of port machinery through the communication protocol ModbusTCP, and uses the pymodbus library to achieve efficient and reliable data communication; An energy feedback judgment module, which marks the feedback status by comparing the torque and rotation speed directions.

3. The energy consumption data acquisition device for a crane according to claim 2, characterized in that The Jetson Orin Nano is installed in the equipment electrical control cabinet of port machinery, is connected to the PLC control system through an RJ45 Ethernet interface, and the data communication link between the Jetson Orin Nano and the PLC control system uses a shielded network cable; the Jetson Orin Nano is equipped with an industrial-grade power supply and is provided with heat dissipation and protection facilities.

4. The energy consumption data acquisition device of a crane according to claim 3, characterized in that, The Jetson Orin Nano is provided with an IO interface, an external button is connected through the IO interface, and the Jetson Orin Nano is connected to a touch screen or a display terminal supporting the crane energy consumption data acquisition device through HDMI or Ethernet.

5. The energy consumption data acquisition device for a crane according to claim 2, characterized in that The sampling frequency of the data acquisition module is 100Hz, sampling once every 10ms, and reads the data of the corresponding register in the PLC control system through ModbusTcpClient.

6. The energy consumption data acquisition device for a crane according to claim 2, wherein The data processing module performs data interaction through the network switch and the PLC control system, and obtains the data communicated between the PLC control system and the electric drive.

7. An energy consumption data analysis and processing algorithm for a crane, characterized in that, Including the following steps: S1. Configure the communication parameters of the crane energy consumption data acquisition device, and the communication parameters include the IP address and port number of the PLC control system, and the voltage and current register addresses to be collected. The above communication parameters are set through a graphical interface developed by PyQt5 and saved in a configuration file in JSON format; S2. The data acquisition module reads the data of the corresponding register in the PLC control system through ModbusTcpClient at a sampling frequency of once every 10ms; S3. Use the data processing module to calculate the instantaneous power and cumulative energy consumption value of the motor drive in real time. Adopt a parallel computing strategy and use the multi-threading of Python to optimize the data processing speed; S4. Through the data storage and presentation module, real-time display and record the instantaneous power, cumulative energy consumption data of each drive unit, and the real-time curve graphs of voltage and current, and monitor and record the changes of digital input and output signals; S5. Obtain the torque and speed information output from the electrical driver to the motor through the energy feedback judgment module, make a comparison, and perform energy feedback processing.

8. The data analysis and processing algorithm for crane energy consumption according to claim 7, wherein The S3 includes the following steps: S31. For a three-phase motor load, the real-time instantaneous power calculation formula is: instantaneous power = voltage × current × 1.732 × power factor, where the voltage and current are real-time collected data, and the power factor is measured according to the real-time operating state of the electrical driver or obtained from the parameter table provided by the electrical driver; S32. Integrate the instantaneous power at intervals of 10 ms to calculate the cumulative energy consumption value of each electrical driver.

9. The data analysis and processing algorithm for crane energy consumption according to claim 7, characterized in that, The S5 includes the following steps: S51. The energy feedback judgment module makes an energy feedback judgment. When the torque and the motor speed have the same sign, it is in the energy consumption state at this time. When the torque and the speed have opposite signs, it is in the energy feedback state; S52. According to the judgment of the energy feedback judgment module, perform energy feedback calculation.

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