WINCC system for fusion casting data acquisition and alarm assistance

Abstract

The invention relates to the technical field of refrigeration through pipe processing, in particular to a WINCC system for fusion casting data acquisition and alarm assistance, which comprises a data acquisition module, a data processing module, a visual monitoring and operation interface, an intelligent alarm and fault diagnosis module and a historical data management and analysis platform, the high-precision temperature sensor, the high-precision pressure sensor, the high-precision flow sensor and the high-precision liquid level sensor are adopted, and various physical parameters in the casting process can be accurately collected; and the data processing module carries out real-time filtering and smoothing processing on the acquired data by using an advanced digital filtering algorithm, so that noise and abnormal values are effectively removed, the authenticity and reliability of the data are ensured, and a solid data basis is provided for subsequent analysis and decision making.

Description

Technical Field

[0001] The invention relates to the technical field of refrigeration pipe processing, in particular to a WINCC system for melting and casting data collection and alarm assistance. Background Art

[0002] In the casting process, precise control and monitoring of various process parameters are crucial to ensuring product quality, improving production efficiency, and ensuring production safety. Casting involves high temperatures, high pressures, and complex physical and chemical reactions, such as metal melting and pouring. Even small changes in parameters like temperature, pressure, flow rate, and liquid level can significantly impact the quality of the final product, leading to defects such as cracks, pores, and uneven composition.

[0003] Traditional methods of collecting and monitoring melting and casting data rely primarily on manual observation and simple instrument measurements, which present numerous limitations. Manual observation is not only labor-intensive but also prone to human error, making it impossible to achieve real-time, continuous, and accurate monitoring. Simple instrument measurements can usually only obtain limited parameter information, and the data recording and processing methods are relatively primitive, making comprehensive and in-depth data analysis difficult. In addition, traditional methods are not timely and accurate in terms of alarms, often only sounding alarms when the problem has become more serious. This makes it difficult for operators to take effective adjustment measures in a timely manner, resulting in a high defective rate in the production process, increased maintenance costs for production equipment, and even potential safety accidents, bringing huge economic losses and safety risks to the company.

[0004] Therefore, we propose a WINCC system for melting and casting data collection and alarm assistance to solve the above problems. Summary of the Invention

[0005] In view of the problems existing in the prior art, the present invention discloses a WINCC system for melting and casting data collection and alarm assistance. The technical solution adopted is that the WINCC system includes a data collection module, a data processing module, a visual monitoring and operation interface, an intelligent alarm and fault diagnosis module, and a historical data management and analysis platform;

[0006] The data acquisition module is connected to the melting and casting equipment through sensors, and can collect various process parameters in the melting and casting process in real time, and convert them into digital signals and transmit them to the data processing module;

[0007] Data processing module: It uses advanced digital filtering algorithms to filter and smooth the received digital signals in real time, remove noise and outliers, ensure the authenticity and reliability of the data, and further analyze and calculate the data according to the preset logic and algorithm, providing a reliable data basis for subsequent monitoring and alarming;

[0008] Visual monitoring and operation interface: The intuitive and user-friendly graphical interface displays real-time data and equipment status of the casting process. Operators can clearly understand the real-time status of the casting production through this module, making it easier to identify potential problems and make adjustments in a timely manner.

[0009] Intelligent alarm and fault diagnosis module: Dynamic alarm thresholds are set based on the standard parameter range of the casting process and the statistical analysis results of historical data. When the system detects a parameter anomaly, an audible and visual alarm is immediately triggered, and detailed alarm information pops up on the monitoring interface. The system automatically records the detailed information of the alarm event and stores it in the historical database for subsequent query and analysis. Through comprehensive analysis of alarm information and historical data, the source of the fault can be quickly and accurately located, and corresponding solutions can be provided to help maintenance personnel quickly troubleshoot the problem and reduce downtime;

[0010] Historical data management and analysis platform: All collected data are stored in time series and provide powerful data query and analysis functions. Operators can query historical data based on time range, parameter type and other conditions. At the same time, the system can conduct in-depth mining and analysis of historical data, providing a scientific basis for optimizing melting and casting process parameters and improving product quality.

[0011] As a preferred technical solution of the present invention, the sensors include high-precision temperature sensors, pressure sensors, flow sensors and liquid level sensors, which can accurately collect various physical parameters during the melting and casting process.

[0012] As a preferred technical solution of the present invention, the advanced digital filtering algorithm is one of Kalman filtering and wavelet transform.

[0013] As a preferred technical solution of the present invention, the intuitive and friendly graphical interface is one or a combination of real-time animation, trend curve, instrument panel, and report.

[0014] As a preferred technical solution of the present invention, the detailed alarm information includes the alarm parameter name, current value, alarm time, possible fault cause and recommended treatment measures.

[0015] As a preferred technical solution of the present invention, the data storage adopts a combination of structured and unstructured methods to ensure the integrity and retrievability of the data.

[0016] Beneficial effects of the present invention:

[0017] 1. Improve data acquisition accuracy and reliability: The present invention uses high-precision temperature sensors, pressure sensors, flow sensors, and liquid level sensors to accurately collect various physical parameters during the casting process. At the same time, the data processing module uses advanced digital filtering algorithms to filter and smooth the collected data in real time, effectively removing noise and outliers, ensuring the authenticity and reliability of the data, and providing a solid data foundation for subsequent analysis and decision-making;

[0018] 2. Realize real-time and accurate monitoring and convenient operation: The visual monitoring and operation interface displays real-time data and equipment status of the melting and casting process through intuitive and friendly graphical interfaces such as real-time animation, trend curves, dashboards, and reports. Operators can understand the production situation at a glance, identify potential problems in a timely manner, and make adjustments. Operators can also conveniently control the melting and casting equipment remotely through this interface, such as adjusting process parameters, starting or stopping equipment, etc., greatly improving operational convenience and production efficiency;

[0019] 3. Intelligent alarm and rapid fault diagnosis and location: The intelligent alarm and fault diagnosis module sets dynamic alarm thresholds based on the casting process standards and the statistical analysis results of historical data. When the parameters are abnormal, it can immediately trigger the sound and light alarm, and pop up detailed alarm information on the monitoring interface, including the alarm parameter name, current value, alarm time, possible fault cause and recommended treatment measures. Through comprehensive analysis of alarm information and historical data, it can quickly and accurately locate the source of the fault, provide solutions, and help maintenance personnel quickly troubleshoot the fault, significantly reducing downtime and production losses;

[0020] 4. Deeply mine historical data to optimize processes: The historical data management and analysis platform stores all collected data in time series and provides powerful data query and analysis functions. Operators can query historical data based on conditions such as time range and parameter type. The system can also conduct in-depth mining and analysis of historical data. For example, through data trend analysis and correlation analysis, the inherent relationship between different parameters can be found. This provides a scientific basis for optimizing melting and casting process parameters and improving product quality, helping enterprises to continuously improve production processes and enhance market competitiveness.

[0021] 5. Improve overall production management and safety: The system of the present invention comprehensively covers the data collection, monitoring, alarm and data analysis links of smelting and casting production, realizing the automation and intelligent management of the production process. This not only helps to improve production efficiency, reduce production costs and improve product quality, but also effectively prevents the occurrence of safety accidents, ensures the safety of personnel and equipment on the production site, and promotes the sustainable development of smelting and casting enterprises. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0023] Figure 1 This is a structural diagram of the present invention. DETAILED DESCRIPTION

[0024] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0025] like Figure 1As shown, the present invention discloses a WINCC system for data collection and alarm assistance for melting and casting. The technical solution adopted is that the WINCC system includes a data collection module, a data processing module, a visual monitoring and operation interface, an intelligent alarm and fault diagnosis module and a historical data management and analysis platform; the data collection module: is connected to the melting and casting equipment through a sensor, and can collect various process parameters in the melting and casting process in real time, and convert them into digital signals for transmission to the data processing module; the data processing module: uses advanced digital filtering algorithms to perform real-time filtering and smoothing on the received digital signals, remove noise and abnormal values, ensure the authenticity and reliability of the data, and further analyze and calculate the data according to preset logic and algorithms, providing a reliable data basis for subsequent monitoring and alarming; the visual monitoring and operation interface: displays the real-time data and equipment status of the melting and casting process through an intuitive and friendly graphical interface, and the operator can understand the melting and casting production at a glance through this module Real-time situation, easy to discover potential problems and make adjustments in time; Intelligent alarm and fault diagnosis module: According to the standard parameter range of the melting and casting process and the statistical analysis results of historical data, dynamic alarm thresholds are set. When the system detects a parameter abnormality, it immediately triggers an audible and visual alarm, and a detailed alarm message pops up on the monitoring interface. The system automatically records the detailed information of the alarm event and stores it in the historical database for subsequent query and analysis. Through the comprehensive analysis of the alarm information and historical data, it can quickly and accurately locate the source of the fault and provide corresponding solutions to help maintenance personnel quickly troubleshoot and reduce downtime; Historical data management and analysis platform: All collected data are stored in time series and provide powerful data query and analysis functions. Operators can query historical data according to time range, parameter type and other conditions. At the same time, the system can conduct in-depth mining and analysis of historical data to provide a scientific basis for optimizing melting and casting process parameters and improving product quality.

[0026] As a preferred technical solution of the present invention, the sensors include high-precision temperature sensors, pressure sensors, flow sensors and liquid level sensors, which can accurately collect various physical parameters during the melting and casting process.

[0027] As a preferred technical solution of the present invention, the advanced digital filtering algorithm is one of Kalman filtering and wavelet transform.

[0028] As a preferred technical solution of the present invention, the intuitive and friendly graphical interface is one or a combination of real-time animation, trend curve, instrument panel, and report.

[0029] As a preferred technical solution of the present invention, the detailed alarm information includes the alarm parameter name, current value, alarm time, possible fault cause and recommended treatment measures.

[0030] As a preferred technical solution of the present invention, the data storage adopts a combination of structured and unstructured methods to ensure the integrity and retrievability of the data.

[0031] Working principle:

[0032] S1. System Installation and Debugging: At the casting production site, install and connect various sensors, data acquisition cards, servers, monitoring terminals and other hardware equipment according to system design requirements, ensuring that the equipment is installed in a reasonable location and the connection lines are firm and reliable to avoid signal interference and transmission loss; install the WINCC software platform and configure the system, including database connection settings, communication parameter configuration, user rights management, etc.; calibrate and debug the data acquisition unit to ensure that the sensors can accurately collect data;

[0033] S2. Data acquisition and transmission: The data acquisition module collects data from various sensors on the casting equipment in real time according to a predetermined sampling period, and transmits the data to the data processing module through communication methods such as industrial Ethernet;

[0034] S3. Data Processing and Analysis: After receiving the data, the intelligent data processing module first performs data preprocessing, including filtering, denoising, and outlier removal. Then, it uses pre-trained data analysis algorithms to analyze and process the data in real time. For example, by analyzing the trend of temperature data, it can predict the changing trend of the melt temperature and adjust the heating power in advance to ensure the stability of the melt temperature. Based on the data analysis results, the system automatically generates various reports and statistical charts, such as daily reports, weekly reports, monthly reports, parameter trend charts, and statistical histograms, providing production managers with intuitive data display and decision-making basis.

[0035] S4. Monitoring and Alarm: The visual monitoring and operation interface displays various parameters and equipment status of the melting and casting process in real time. Operators can intuitively understand the real-time situation of melting and casting production through the monitoring interface, such as the change curve of the melt temperature, the numerical display of the pressure in the furnace, the real-time monitoring of the metal flow rate, and the operating status of the equipment. When the system detects that the parameters exceed the alarm threshold, the alarm mechanism is immediately triggered. The alarm information is issued through the sound and light alarm, and the alarm content is displayed in eye-catching colors and flashing icons on the monitoring interface. At the same time, the system automatically records the alarm event, including the alarm time, alarm parameters, alarm value and other information for subsequent query and analysis.

[0036] S5. Fault diagnosis and handling: When an alarm event occurs, the precise alarm and fault diagnosis system automatically initiates the fault diagnosis program. By comprehensively analyzing the alarm information, historical data, and equipment operating status, and utilizing the knowledge base and reasoning mechanism of the fault diagnosis expert system, the cause of the fault can be quickly located. Based on the fault diagnosis results, the system provides detailed fault solutions and repair suggestions to guide maintenance personnel in troubleshooting. Maintenance personnel can view fault diagnosis reports and repair instructions through the monitoring interface, quickly take appropriate maintenance measures, repair the faulty equipment, and resume production.

[0037] S6. Historical data storage and analysis. The historical data storage and analysis module stores all collected data and regularly backs up and organizes historical data. Operators can query historical data through this module when needed and use the data analysis tools provided by the system to conduct data mining and analysis to provide a reference for the optimization of production processes.

[0038] The circuit connection involved in the present invention is a common method used by those skilled in the art, and technical inspiration can be obtained through limited experiments. It belongs to the widely used existing technology.

[0039] Components not described in detail herein are prior art.

[0040] Although the specific embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by ordinary technicians in this field, various changes can be made without departing from the purpose of the present invention. Modifications or deformations that do not involve creative work are still within the scope of protection of the present invention.

Claims

1. A WINCC system for melting and casting data collection and alarm assistance, characterized in that: The WINCC system includes a data acquisition module, a data processing module, a visual monitoring and operation interface, an intelligent alarm and fault diagnosis module, and a historical data management and analysis platform; the data acquisition module is connected to the casting equipment through sensors, and can collect various process parameters in the casting process in real time, and convert them into digital signals for transmission to the data processing module; the data processing module uses advanced digital filtering algorithms to filter and smooth the received digital signals in real time, remove noise and abnormal values, ensure the authenticity and reliability of the data, and further analyze and calculate the data according to the preset logic and algorithm, providing a reliable data basis for subsequent monitoring and alarming; the visual monitoring and operation interface is displayed through an intuitive and friendly graphical interface The module displays real-time data and equipment status of the melting and casting process. Operators can use this module to understand the real-time situation of melting and casting production at a glance, making it easy to discover potential problems and make adjustments in a timely manner. Intelligent alarm and fault diagnosis module: According to the standard parameter range of the melting and casting process and the statistical analysis results of historical data, dynamic alarm thresholds are set. When the system detects parameter abnormalities, it immediately triggers sound and light alarms, and detailed alarm information pops up on the monitoring interface. The system automatically records detailed information of the alarm event and stores it in the historical database for subsequent query and analysis. Through comprehensive analysis of alarm information and historical data, it can quickly and accurately locate the source of the fault and provide corresponding solutions to help maintenance personnel quickly troubleshoot the fault and reduce downtime. Historical data management and analysis platform: All collected data are stored in time series and provide powerful data query and analysis functions. Operators can query historical data based on time range, parameter type and other conditions. At the same time, the system can conduct in-depth mining and analysis of historical data, providing a scientific basis for optimizing melting and casting process parameters and improving product quality.

2. The WINCC system for melting and casting data acquisition and alarm assistance according to claim 1 is characterized in that: The sensors include high-precision temperature sensors, pressure sensors, flow sensors and liquid level sensors, which can accurately collect various physical parameters during the melting and casting process.

3. The WINCC system for melting and casting data acquisition and alarm assistance according to claim 1 is characterized in that: The advanced digital filtering algorithm is one of Kalman filtering and wavelet transform.

4. The WINCC system for melting and casting data collection and alarm assistance according to claim 1 is characterized in that: The intuitive and friendly graphical interface is one or a combination of real-time animation, trend curve, instrument panel, and report.

5. The WINCC system for melting and casting data collection and alarm assistance according to claim 1 is characterized in that: The detailed alarm information includes the alarm parameter name, current value, alarm time, possible fault cause and recommended treatment measures.

6. The WINCC system for melting and casting data collection and alarm assistance according to claim 1 is characterized in that: The data storage adopts a combination of structured and unstructured methods to ensure the integrity and retrievability of the data.

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