Equipment fault and video monitoring linkage system applied to production field

Abstract

The invention discloses an equipment fault and video monitoring linkage system applied to a production field, which comprises a video system and a control system, and the video system and the control system are respectively communicated through a convergence switch; the video system comprises a camera terminal device, a network access switch, a video server, a hard disk video recorder, a gateway server and a video monitoring station, and the control system comprises an operation station, a PLC system and a convergence switch. The invention belongs to the technical field of production field monitoring, and particularly provides a video monitoring system which is used for solving the problems that related monitoring videos cannot be obtained in time when equipment breaks down and the real-time effect of video monitoring cannot be fully displayed due to the fact that the number of equipment monitoring points is not matched with the number of video monitoring screens in an existing production field. Therefore, the accident handling efficiency and the production safety are influenced.

Description

Technical Field

[0001] The present invention belongs to the technical field of production site monitoring, and in particular relates to a system for linking equipment failure and video monitoring in a production site. Background Art

[0002] Production sites typically have hundreds of equipment monitoring points installed to monitor their operating status in real time. However, the limited number of video surveillance screens often only allows for real-time viewing of a dozen or so images. When an equipment incident occurs, the relevant surveillance video often fails to be displayed on the screen in a timely manner. This prevents operators from promptly identifying and shutting down the faulty equipment, potentially escalating the incident. Currently, surveillance video information is mostly used only as a post-incident analysis tool, and the real-time benefits of video surveillance are not fully realized.

[0003] In actual production, due to the numerous monitoring points on equipment and the limited number of video surveillance screens, operators struggle to fully and promptly understand equipment operating conditions. When equipment malfunctions, the inability to quickly locate the fault point and promptly address the abnormality poses a serious threat to production safety. Therefore, it is crucial to link video with equipment failures, ensuring that relevant surveillance video is projected onto the monitoring screen in a timely manner. Summary of the Invention

[0004] The technical problem to be solved by the present invention is that in existing production sites, due to the mismatch between the number of equipment monitoring points and video monitoring screens, relevant monitoring videos cannot be obtained in a timely manner when equipment fails, and the real-time function of video monitoring cannot be fully demonstrated, thereby affecting the efficiency of accident handling and production safety.

[0005] In order to solve the above problems, the technical solutions adopted by the present invention are as follows:

[0006] The present invention proposes a system for linking equipment failure and video monitoring at a production site, comprising a video system and a control system, wherein the video system and the control system communicate with each other through a convergence switch.

[0007] The video system includes:

[0008] Camera terminal equipment, used to collect video surveillance signals from the production site;

[0009] A network access switch, connected to the camera terminal device, for receiving and forwarding video surveillance signals;

[0010] a video server connected to the network access switch and configured to store and process video surveillance signals;

[0011] a hard disk video recorder, connected to the network access switch, for backing up video surveillance signals;

[0012] A gateway server connected to the video server and the hard disk recorder for protocol conversion and data distribution;

[0013] A video surveillance station, connected to the gateway server, for real-time display and management of video surveillance signals;

[0014] The control system includes:

[0015] Operation station, used to receive user instructions and display equipment operating status;

[0016] a PLC system connected to the PLC system for performing logic control of the production equipment;

[0017] The convergence switch is connected to the PLC system and the operation station, and is used to realize data interaction between the PLC and the video system.

[0018] Preferably, the aggregation switch is respectively connected to the network access switch and is used to realize data communication between the video system and the control system. The setting of the aggregation switch can open up the network data flow channel between the video system and the control system, so that the Internet of Things can directly access the control system PLC. The PLC system directly controls the operation of various equipment on the production site and the collection of process parameters and displays and intervenes in the operation station.

[0019] Preferably, the gateway server adopts an Internet of Things gateway server, which is a key functional device of this video surveillance linkage system. It can receive the alarm signal of the PLC system, and call out the corresponding video signal from the video server according to the alarm signal, and display it in a pop-up window and alarm in the video surveillance station.

[0020] Preferably, when a production site device fails:

[0021] The PLC system detects equipment anomalies and sends an alarm signal to the IoT gateway;

[0022] The IoT gateway server analyzes the alarm signal and retrieves the monitoring video stream of the associated device from the video server;

[0023] The video surveillance station automatically displays the fault image in a pop-up window and triggers an audible and visual alarm;

[0024] The operator can quickly locate the fault point based on the screen and remotely intervene in equipment operation through the PLC system.

[0025] Preferably, the video surveillance linkage system has multiple application scenarios such as embedded video display, camera pan / tilt control, alarm linkage, function group linkage, video playback and screen capture.

[0026] Preferably, the PLC system uses a Siemens PLC, programmed in the Botu V19 environment, to program the factory equipment's motion logic, collect equipment motion status and data in real time, and receive various commands from the operator station. The IoT gateway server's gateway configuration service, DH-IEGIMF-E, communicates with the PLC and video server via TCP / IP to match alarm signals with video streams.

[0027] Preferably, the operating station is configured with WINCC-V7.5 software, which displays the device status and data collected by the PLC system, sends instructions to the PLC via the screen, archives data, and issues alerts for system alarms. The operating station integrates an integrated security monitoring platform, Dahua ICC-NClient software, supporting device status visualization and remote control.

[0028] By adopting the above scheme, the beneficial effects achieved by the present invention are as follows:

[0029] 1. Network cameras digitize video signals and convert them into data streams that conform to network transmission protocols. This connects the proprietary video signal network with the PLC system's real-time data network. Combining technologies such as video capture and image analysis enables multi-scenario applications. When an abnormality occurs in the production system, the system automatically triggers the corresponding alarm and response. The video surveillance station immediately displays monitoring video of the faulty equipment, enabling personnel to quickly locate the fault point and promptly handle the abnormality, improving the efficiency and accuracy of safety management.

[0030] 2. The linkage system can monitor the equipment status in real time. Once the equipment fails, the relevant video will be projected immediately, avoiding the expansion of accidents caused by failure to discover the fault in time, reducing the phenomenon of missed faults, and providing strong support for ensuring production safety.

[0031] 3. The system bridges the gap between the video surveillance system and the production control system through the Internet of Things, enabling interconnection between the production control system's alarm information and video surveillance. The entire system can automatically trigger alarms and link video according to preset rules, reducing manual intervention and improving the system's intelligence level. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a system architecture diagram of a system for linking equipment failure and video monitoring at a production site provided by the present invention;

[0033] Figure 2 Software engineering environment diagram for the PLC system using Botu V19;

[0034] Figure 3 It is the engineering equipment view;

[0035] Figure 4 It is the engineering network view;

[0036] Figure 5 Programming views for projects;

[0037] Figure 6 Software engineering environment for the operation station 1;

[0038] Figure 7 Software engineering environment 2 for the operation station;

[0039] Figure 8 Software engineering environment for the operating station III;

[0040] Figure 9 It is the preview interface of the integrated security monitoring platform;

[0041] Figure 10 This is the screen preview interface 1;

[0042] Figure 11 This is the second screen preview interface;

[0043] Figure 12 Indicates the video source Figure 1 ;

[0044] Figure 13 Indicates the video source Figure 2 ;

[0045] Figure 14 This is the platform interface 1;

[0046] Figure 15 It is the device management interface;

[0047] Figure 16 It is an automatic search interface;

[0048] Figure 17 This is the second platform interface;

[0049] Figure 18 Configure the page for monitoring;

[0050] Figure 19 Set up the page for configuration;

[0051] Figure 20 It is the interface of the alarm plan platform;

[0052] Figure 21 Configure page 1 for the alarm plan;

[0053] Figure 22 Configure page 2 for the alarm plan;

[0054] Figure 23 Configure page three for the alarm plan;

[0055] Figure 24 Set up a graph for alarm parameters;

[0056] Figure 25 Configuration tool page for gateway configuration services;

[0057] Figure 26 For the new project page;

[0058] Figure 27 Basic configuration for acquisition channel;

[0059] Figure 28 It is the communication parameter configuration interface;

[0060] Figure 29 Configure the acquisition device;

[0061] Figure 30 It is the basic attribute map of the collection point;

[0062] Figure 31 It is the I / O connection property of the acquisition point;

[0063] Figure 32 To save the project schematic.

[0064] The accompanying drawings are used to provide further understanding of the present invention and constitute a part of the specification. They are used to explain the present invention together with the embodiments of the present invention and do not constitute a limitation of the present invention. DETAILED DESCRIPTION

[0065] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments; based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0066] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the present invention.

[0067] Example 1

[0068] like Figure 1As shown in the figure, the present invention proposes a system for linking equipment failures and video surveillance at production sites. The system comprises a video system and a control system, which communicate via a convergence switch. This system supports multiple application scenarios, including embedded video display, camera pan / tilt control, alarm linkage, function group linkage, video playback, and screen capture.

[0069] The video system includes:

[0070] Camera terminal equipment, used to collect video surveillance signals from the production site;

[0071] The network access switch is connected to the camera terminal device and is used to receive and forward video monitoring signals; the camera terminal device at the production site can store the video monitoring signals in the hard disk recorder and the video server through the network access device.

[0072] The video server, connected to the network access switch, is used to store and process video surveillance signals. It is suitable for network video surveillance applications, such as those requiring remote real-time monitoring and centralized management. It can be widely used anywhere to continuously transmit images in real time, even in environments where cabling is unsuitable, allowing remote monitoring and recording using wireless broadband networks.

[0073] a hard disk video recorder, connected to the network access switch, for backing up video surveillance signals;

[0074] The gateway server is connected to the video server and the hard disk recorder for protocol conversion and data distribution. It is a key functional device that uses an Internet of Things gateway server to receive the alarm signal of the PLC system, and according to the alarm signal, it calls out the corresponding video signal from the video server, and displays it in a pop-up window and alarms in the video monitoring station.

[0075] The video monitoring station is connected to the gateway server and is used for real-time display and management of video monitoring signals.

[0076] Among them, the control system includes:

[0077] Operation station, used to receive user instructions and display equipment operating status;

[0078] a PLC system connected to the PLC system for performing logic control of the production equipment;

[0079] The convergence switch is connected to the PLC system and the operation station, and is used to realize data interaction between the PLC and the video system.

[0080] In addition, the aggregation switch is respectively connected to the network access switch to realize data communication between the video system and the control system. The setting of the aggregation switch can open up the network data flow channel between the video system and the control system, so that the Internet of Things can directly access the control system PLC. The PLC system directly controls the operation of various equipment on the production site and the collection of process parameters and displays and intervenes in the operation station.

[0081] Through this technical solution, network cameras digitize video signals and convert them into data streams that conform to network transmission protocols. This connects the proprietary video signal network with the real-time data network of the PLC control system. Combined with video capture and image analysis technologies, this solution enables multi-scenario applications. When an anomaly occurs in the production system, the system automatically triggers the appropriate alarm and response, and the video feed of the faulty equipment is immediately displayed in the video surveillance station, enabling personnel to quickly locate the fault point and address the anomaly promptly. The IoT gateway bridges the gap between the video surveillance system and the production control system, enabling interconnection between the production control system's alarm information and video surveillance. By implementing these features, the video surveillance platform provides a more efficient and intelligent security monitoring solution, improving the efficiency and accuracy of security management, reducing missed fault reports, and providing strong support for ensuring production safety.

[0082] Example 2

[0083] The video surveillance linkage system in the factory production area involves four major software platforms: Siemens Portal V19, Siemens WINCC-V7.5, gateway configuration service DH-IEGIMF-E, and integrated security monitoring platform ICC-NClient.

[0084] The PLC system uses Siemens PLC, the programming environment is Botu V19, and the software engineering environment is as follows Figure 2 As shown, the action logic of the equipment in the factory area is programmed, and the equipment movement status and data are collected in real time, and various instructions sent by the operation station are received.

[0085] The engineering equipment view of Botu V19 is as follows Figure 3 As shown, the project network view is as follows Figure 4 As shown, the engineering programming view is as follows Figure 5 shown.

[0086] Preferably, the software configuration of the operating station is WINCC-V7.5, and its software engineering environment is as follows Figure 6 、 Figure 7 and Figure 8 As shown, the device status and data collected by the PLC system are displayed, and instructions can be sent to the PLC through the screen. At the same time, the data is archived and the system alarm information is alerted.

[0087] Preferably, the operation station integrates an integrated security monitoring platform and Dahua ICC-N Client software, supporting device status visualization and remote control.

[0088] Among them, the integrated security monitoring platform, ICC-N Client, is a Dahua management platform with rich access capabilities and adaptability to a variety of video devices. This platform not only supports access to mainstream market standard protocols, including national standards GB / T 28181, RTMP, RTSP / ONVIF, Ministry standards JT808, and GA / T 1400, but also provides SDK development interfaces for compatible access to devices that do not conform to standard protocols, meeting the access requirements of different scenarios. It offers intuitive management capabilities for various videos, such as pulling the video platform's catalog and distinguishing videos by type. The status of currently connected videos can be intuitively displayed through interfaces and screens, making debugging and maintenance very convenient.

[0089] 1. The operation steps of the integrated platform ICC-N video access function are as follows:

[0090] Step 1.1: If Figure 9 As shown, double-click the platform management client software to enter the integrated management and control intelligent assistance platform and enter the screen preview interface.

[0091] Step 1.2: If Figure 10 As shown in the figure, the left side of the screen preview interface is the video source menu, and the right side is the screen preview interface. Figure 11 As shown, there is a picture in the lower right corner of the interface. After selecting several pictures, click on the video source you want to watch on the left. The video source is as follows Figure 12 and Figure 13 shown.

[0092] 2. Configuration of the platform IoT video linkage pop-up function:

[0093] Step 2.1 Bind device:

[0094] 2.1.1 Click "Device Management" to enter the device interface, such as Figure 14 shown.

[0095] 2.1.2 Click "Auto Search" and select encoder as the type. The camera device that has not been added can be automatically searched. Figure 15 As shown; you can also click "Add" to add manually, such as Figure 16 shown.

[0096] Check the device you want to add, click "Add to Management", and then click "Finish". It will prompt that the device has been added successfully.

[0097] Step 2.2 Monitoring Configuration:

[0098] 2.2.1 Monitoring Configuration: Click Monitoring Configuration to enter the monitoring configuration interface, such as Figure 17 shown.

[0099] 2.2.2 Click the Add button to enter the configuration interface, add the monitoring configuration and click Save. Figure 18 shown.

[0100] 2.2.3 According to business needs, click "Save" after configuring the data to save the settings, such as Figure 19 shown.

[0101] Step 2.3 Alarm plan configuration:

[0102] 2.3.1 Click “Alarm Plan” to enter the alarm plan interface. Figure 20 shown.

[0103] 2.3.2 Enter the new alarm plan interface and fill in the name, such as Figure 21-23 shown.

[0104] 2.3.3 Click the node device variable name to set the alarm parameters, such as Figure 24 As shown in the figure, it contains basic information and alarm threshold configuration.

[0105] As a preferred embodiment:

[0106] The IoT gateway server's gateway configuration service, DH-IEGIMF-E, communicates with the PLC and video server via TCP / IP, matching alarm signals with video streams. As a key component of the entire linkage system, it plays a crucial role. It receives alarm signals from the PLC system and, based on the alarm signals, retrieves the corresponding video signal from our video server.

[0107] The engineering configuration of the IoT gateway server in the video system includes the following steps:

[0108] S1 Create Project:

[0109] To configure a project, you first need to create a project. The specific steps are as follows.

[0110] Double-click the Dahua IoT Gateway configuration software to enter the configuration tool interface, such as Figure 25 As shown, click "New Project" in the upper left corner of the tab bar, and the "New Project" dialog box will pop up, as shown Figure 26 As shown;

[0111] S2 adds acquisition channels:

[0112] After the project is established, you need to configure data collection in the project. First, create a collection channel. The specific operation method is as follows.

[0113] Select the "Data Acquisition" tab, under the "Data Acquisition" tab, click the "New Channel" button, and the "New Channel" dialog box will pop up. Figure 27 As shown;

[0114] After selecting the channel protocol, the corresponding communication parameter configuration interface will be expanded according to the different protocols, such as Figure 28 As shown;

[0115] The default communication method is TCP network communication. You can switch between TCP network communication and serial communication by clicking the "Port Type" drop-down box to the right of "Communication Port." If using TCP network communication, you need to specify the IP address and communication port of the device being collected. If using serial communication, you need to specify parameters such as the serial port number, communication rate, data bits, stop bits, parity, and serial mode. After specifying the required parameters, click "OK" to save the configuration and complete the addition of the acquisition channel.

[0116] S3 adds a collection device:

[0117] After adding the acquisition channel, you need to add an acquisition device under the acquisition channel. The specific operation method is as follows.

[0118] Select the corresponding acquisition channel node under the "Data Acquisition" node in the left project pane, click the "Add Device" button above, and the "New Device" dialog box will pop up. Figure 29 As shown;

[0119] In the New Device dialog box, configure the basic parameters of the device. The meanings of the basic parameters are shown in Table 1.

[0120] Table 1 Basic parameters of equipment

[0121]

[0122] After configuring the basic parameters of the device, click "Confirm" to save the configuration.

[0123] S4 adds a collection point:

[0124] After adding the collection device, you need to add collection points under the collection device. The specific operation method is as follows.

[0125] Select the corresponding acquisition device node under the "Data Acquisition" node in the left project pane, and then double-click the left mouse button in the blank area of the table on the right to pop up the "Add Measurement Point" dialog box, as shown in the following example: Figure 30 As shown;

[0126] Switch to the "I / O Connection" page, click the "More" icon, and configure the parameters according to the actual situation, such as Figure 31 shown.

[0127] Then click "OK" to save the configuration and complete the addition of the collection point. If there are multiple measurement points, you can repeat the above steps to complete the addition or use the batch addition measurement point function.

[0128] S5 installation project:

[0129] After completing the above steps, you need to save the project and upload it to the gateway. Figure 32 shown.

[0130] Save the project and upload it to the gateway. For the first download, select Download Driver.

[0131] After the entire system is configured, the device failure and video can be linked according to the configuration plan. When a device fails, the related video images will be projected onto the monitoring screen in real time.

[0132] Finally, it should be noted that the above specific implementation methods are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

[0133] In summary, if ordinary technicians in this field are inspired by this and design structural methods and embodiments similar to this technical solution without creatively designing them without departing from the purpose of the invention, they should all fall within the scope of protection of the invention.

Claims

1. A system for linking equipment failure and video monitoring at a production site, characterized in that: It includes two parts: video system and control system, which communicate with each other through a convergence switch. The video system includes: Camera terminal equipment, used to collect video surveillance signals from the production site; A network access switch, connected to the camera terminal device, for receiving and forwarding video surveillance signals; a video server connected to the network access switch and configured to store and process video surveillance signals; a hard disk video recorder, connected to the network access switch, for backing up video surveillance signals; A gateway server connected to the video server and the hard disk recorder for protocol conversion and data distribution; A video surveillance station, connected to the gateway server, for real-time display and management of video surveillance signals; The control system includes: Operation station, used to receive user instructions and display equipment operating status; a PLC system connected to the PLC system for performing logic control of the production equipment; The convergence switch is connected to the PLC system and the operation station, and is used to realize data interaction between the PLC and the video system.

2. The system for linking equipment failure and video surveillance in production sites according to claim 1, characterized in that: The aggregation switch is respectively connected to the network access switch and is used to realize data communication between the video system and the control system. Through the setting of the aggregation switch, the network data flow channel between the video system and the control system can be opened, so that the Internet of Things can directly access the control system PLC. The PLC system directly controls the operation of various equipment on the production site and the collection of process parameters and displays and intervenes in the operation station.

3. The system for linking equipment failure and video surveillance in production sites according to claim 2, characterized in that: The gateway server adopts an Internet of Things gateway server, which is used to receive the alarm signal of the PLC system, and call out the corresponding video signal from the video server according to the alarm signal, and display it in a pop-up window and alarm in the video monitoring station.

4. The system for linking equipment failure and video surveillance in production sites according to claim 3, characterized in that: When a device fails at the production site: The PLC system detects equipment anomalies and sends an alarm signal to the IoT gateway; The IoT gateway server analyzes the alarm signal and retrieves the monitoring video stream of the associated device from the video server; The video surveillance station automatically displays the fault image in a pop-up window and triggers an audible and visual alarm; The operator can quickly locate the fault point based on the screen and remotely intervene in equipment operation through the PLC system.

5. The system for linking equipment failure and video surveillance at a production site according to claim 4, characterized in that: The video surveillance linkage system has multiple application scenarios including embedded video display, camera pan / tilt control, alarm linkage, function group linkage, video playback and screen capture.

6. The system for linking equipment failure and video surveillance in production sites according to claim 5, characterized in that: The PLC system uses Siemens PLC and the programming environment is Botu V19. It programs the action logic of equipment in the factory area, collects equipment movement status and data in real time, and receives various instructions sent by the operation station.

7. The system for linking equipment failure and video surveillance at a production site according to claim 6, characterized in that: The software configuration of the operation station is WINCC-V7.5, which displays the equipment status and data collected by the PLC system, sends instructions to the PLC through the screen, archives the data, and issues warnings for system alarm information.

8. The system for linking equipment failure and video surveillance in production sites according to claim 3, characterized in that: The gateway configuration service DH-IEGIMF-E of the IoT gateway server communicates with the PLC and video server through the TCP / IP protocol to achieve matching of alarm signals and video streams.

9. The system for linking equipment failure and video surveillance in production sites according to claim 7, characterized in that: The operation station integrates an integrated security monitoring platform and Dahua ICC-N Client software, supporting device status visualization and remote control.

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