Crane electrical control system switching value data acquisition and storage optimization method and device

Abstract

The invention discloses a crane electrical control system switching value data acquisition and storage optimization method and device, and relates to the technical field of crane switching value data processing.The method comprises the steps that the operation state of a crane electrical control system is obtained; the operation state comprises starting, operation and fault; on the basis of the operation state, collecting switching value data; performing data optimization processing on the switching value data to obtain optimized data; and performing data compression storage on the optimized data to obtain stored data. The redundancy of the switching value data of the crane electrical control system can be reduced, and the processing efficiency can be improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of crane switch quantity data processing, in particular to a crane electrical control system switch quantity data acquisition and storage optimization method and device. BACKGROUND

[0002] A large amount of switch quantity data (such as contactor state, limit signal, fault alarm, etc.) is generated in the running process of the crane electrical system. The traditional data acquisition method has the following problems:

[0003] Fixed sampling frequency: unable to dynamically adjust according to the device state, resulting in loss of key event data or too much redundant data.

[0004] High storage redundancy: switch quantity data is mostly repeated state signals, directly storing occupies a large amount of space.

[0005] Low processing efficiency: traditional relational database query is slow and difficult to support real-time fault diagnosis.

[0006] Therefore, how to design a crane electrical control system switch quantity data acquisition and storage optimization method and device that can reduce data redundancy and improve processing efficiency has become a technical problem that needs to be solved in the field. SUMMARY

[0007] The purpose of the present application is to provide a crane electrical control system switch quantity data acquisition and storage optimization method and device that can reduce the redundancy of crane electrical control system switch quantity data and improve processing efficiency.

[0008] To achieve the above purpose, the present application provides the following solutions:

[0009] In a first aspect, the present application provides a crane electrical control system switch quantity data acquisition and storage optimization method, which comprises:

[0010] Obtaining the running state of the crane electrical control system; the running state includes: starting, running and fault.

[0011] Based on the running state, the switch quantity data is acquired.

[0012] The switch quantity data is subjected to data optimization processing to obtain the data after optimization processing.

[0013] The data after optimization processing is subjected to data compression storage to obtain the data after storage.

[0014] Optionally, based on the running state, the switch quantity data is acquired, specifically comprising:

[0015] Different acquisition periods are set according to the operating state.

[0016] It is judged whether the operating state is a key switch value, and a judgment result is obtained.

[0017] If the judgment result is yes, an interrupt trigger mode is adopted to read interrupt switch value data, and a state change time and a duration are recorded.

[0018] If the judgment result is no, a polling period mode is adopted to read polling period switch value data based on the acquisition period.

[0019] Optionally, the switch value data is subjected to data optimization processing to obtain optimized data, specifically including:

[0020] The switch value data is subjected to adaptive filtering and debouncing by using a sliding window algorithm to obtain debounced data.

[0021] The debounced data is subjected to noise filtering and state logic verification at an edge node to eliminate invalid data, and the optimized data is obtained.

[0022] Optionally, the optimized data is subjected to data compression storage to obtain stored data, specifically including:

[0023] Based on the optimized data, a state change event and corresponding time window data are screened out.

[0024] When a change frequency of the state change event is greater than a preset number of times, Huffman coding is adopted for binary bit stream compression storage.

[0025] When the change frequency of the state change event is stable, RLE is adopted for storage.

[0026] Optionally, the optimized data is subjected to data compression storage to obtain stored data, and the method further includes:

[0027] The state change event is added with a device ID and a working condition label.

[0028] The RAM is used to store the state change event and corresponding time window data in the last 24 hours.

[0029] After the state change event and corresponding time window data are classified according to time / event, a columnar storage structure is adopted to write into a solid state disk.

[0030] Optionally, the switch value data acquisition and storage optimization method of the crane electrical control system further includes:

[0031] The interrupt switch value data is transmitted to a crane cloud management platform.

[0032] In a second aspect, the application provides a crane electrical control system switching value data acquisition and storage optimization device, which is used to implement the crane electrical control system switching value data acquisition and storage optimization method described in any of the above aspects. The crane electrical control system switching value data acquisition and storage optimization device comprises a crane electrical control system, a signal acquisition module, a processing unit, a storage module, and a crane cloud management platform.

[0033] The crane electrical control system comprises a driving device, a control device, a sensor, and an actuator. A master PLC and a frequency converter are used to achieve precise motor speed regulation and multi-mechanism collaborative control, and are deployed in each electrical cabinet of the crane.

[0034] The signal acquisition module communicates with the crane electrical control system through a CAN bus and is used to acquire switching value data in the master PLC.

[0035] The processing unit comprises:

[0036] An ARM processor is used to run dynamic polling logic.

[0037] An FPGA processor is used to process interrupt triggering and real-time filtering.

[0038] The storage module comprises:

[0039] A RAM cache layer is used to store state change events and corresponding time window data in the last 24 hours.

[0040] A solid-state storage layer is used to store state change events and corresponding time window data in a columnar storage structure after classification by time / event.

[0041] The crane cloud management platform is used to receive interrupted switching value data, support remote monitoring and fault early warning, and provide device health reports and abnormal data backtracking functions.

[0042] Optionally, the signal acquisition module comprises:

[0043] A multi-channel optocoupler isolation input circuit is used to support 0-24V switching value signal acquisition.

[0044] An RC filter circuit is used to suppress high-frequency noise.

[0045] Optionally, the processing unit further comprises:

[0046] An internal clock module is used to ensure that the time stamp accuracy of multi-channel data is less than or equal to a preset value.

[0047] Optionally, the storage module further comprises:

[0048] A power-off protection circuit is configured to ensure that the buffered data is completely written into the storage medium when a sudden power failure occurs.

[0049] According to the embodiments provided in the application, the application discloses the following technical effects:

[0050] The application provides a crane electrical control system switching value data acquisition and storage optimization method and device. First, the running state of the crane electrical control system is acquired. The running state includes starting, running and failure, which can lock the key monitoring object and reduce the generation of invalid data. Second, based on the running state, switching value data is acquired, which can ensure that the acquired switching value data is directly related to the current working condition, avoid irrelevant data from occupying transmission and storage resources, and reduce data redundancy. Then, the switching value data is subjected to data optimization processing to obtain the data after optimization processing, which can ensure that the switching value data can truly reflect the actual state of the electrical control system, avoid false data from misleading subsequent analysis, and at the same time, the optimized data is more concise and the logic is clearer, which can reduce the calculation burden for subsequent compressed storage and analysis. Finally, the data after optimization processing is subjected to data compression storage to obtain the data after storage, which can reduce the storage capacity. The crane has a long running cycle and a large amount of switching value data, and the compression can significantly reduce the occupancy rate of the storage device such as a hard disk, reduce the hardware cost, at the same time, the compressed data set is smaller, the transmission and loading speed is faster when querying the historical state subsequently, and the fast analysis is facilitated. The application can ensure the effectiveness and reliability of the data, reduce the cost and complexity of data management, provide a high-quality data basis for the state monitoring, fault diagnosis and life prediction of the crane electrical control system, and indirectly improve the safety and stability of the equipment operation. BRIEF DESCRIPTION OF DRAWINGS

[0051] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the following will briefly introduce the drawings needed in the embodiments. Obviously, the drawings in the following description are only some embodiments of the application, and for those skilled in the art, other drawings can also be obtained from these drawings without creative labor.

[0052] Figure 1 It is an application environment diagram of a crane electrical control system switching value data acquisition and storage optimization method in an embodiment of the application.

[0053] Figure 2 It is a flowchart of a crane electrical control system switching value data acquisition and storage optimization method provided in an embodiment of the application.

[0054] Figure 3A specific work flow diagram of a switch value data acquisition and storage optimization method of a crane electrical control system is provided for an embodiment of the present application.

[0055] Figure 4 A structural diagram of a switch value data acquisition and storage optimization device of a crane electrical control system is provided for an embodiment of the present application. DETAILED DESCRIPTION

[0056] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of protection of the present application.

[0057] The present application provides a switch value data acquisition and storage optimization method and device for a crane electrical control system, which significantly reduces data redundancy and improves processing efficiency through dynamic adjustment of sampling frequency, segmented compression storage and distributed architecture, and is suitable for intelligent transformation and digital efficient management of cranes in port, factory and other scenarios.

[0058] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the present application will be further described in detail below with reference to the drawings and specific embodiments.

[0059] The switch value data acquisition and storage optimization method of the crane electrical control system provided in the embodiments of the present application can be applied to, for example, Figure 1The application environment shown. Among them, the terminal 102 communicates with the server 104 through the network. The data storage system can store the data required by the server 104 to process. The data storage system can be set up separately, or integrated on the server 104, or placed on the cloud or other servers. The terminal 102 can send the obtained running state of the crane electrical control system to the server 104, and the running state includes: start, run and failure; After the server 104 receives the running state of the crane electrical control system, the server 104 collects the on-off data based on the running state; The data optimization processing is carried out on the on-off data, and the optimized data is obtained; The data compression storage is carried out on the optimized data, and the stored data is obtained. The server 104 can feed back the stored data to the terminal 102. In addition, in some embodiments, the crane electrical control system on-off data acquisition and storage optimization method can also be realized by the server 104 or the terminal 102 alone, such as the terminal 102 can directly collect and store the on-off data of the crane electrical control system based on the running state of the crane electrical control system, or the server 104 can collect the running state of the crane electrical control system from the data storage system and collect and store the on-off data of the crane electrical control system based on the running state of the crane electrical control system.

[0060] Among them, the terminal 102 can be but not limited to various desktop computers, notebook computers, smart phones and tablet computers. The server 104 can be realized by an independent server or a server cluster composed of multiple servers, and can also be a cloud server.

[0061] In an exemplary embodiment, as shown in Figure 2 A crane electrical control system on-off data acquisition and storage optimization method is provided, which is executed by a computer device, specifically by a terminal or a server computer device alone, or by a terminal and a server together. In the embodiment of the present application, the method is applied to the server 104 in Figure 1 The following steps S1 to S4 are included. Among them:

[0062] S1: Obtain the running state of the crane electrical control system; The running state includes: start, run and failure.

[0063] S2: Collect on-off data based on the running state.

[0064] S3: Data optimization processing is carried out on the on-off data, and the optimized data is obtained.

[0065] S4: The data compression storage is carried out on the optimized data, and the stored data is obtained.

[0066] Implementing the above steps S1 to S4 can ensure the effectiveness and reliability of the data, reduce the cost and complexity of data management, provide a high-quality data basis for the state monitoring, fault diagnosis and life prediction of the crane electrical control system, and indirectly improve the safety and stability of the equipment operation.

[0067] As an optional implementation, in step S2, switch quantity data is collected based on the operating state, specifically including:

[0068] S21: Different collection periods are set according to the operating state.

[0069] S22: It is judged whether the operating state is a key switch quantity, and a judgment result is obtained.

[0070] S23: If the judgment result is yes, an interrupt trigger mode is adopted to read the interrupted switch quantity data, and the state change time and duration are recorded.

[0071] S24: If the judgment result is no, a polling period mode is adopted to read the polling period switch quantity data based on the collection period.

[0072] As an optional implementation, in step S3, the switch quantity data is subjected to data optimization processing to obtain optimized data, specifically including:

[0073] S31: A sliding window algorithm is adopted to perform adaptive filter debouncing on the switch quantity data to obtain debounced data.

[0074] S32: Noise filtering and state logic verification are performed on the debounced data at the edge node to eliminate invalid data, and the optimized data is obtained.

[0075] As an optional implementation, in step S4, the optimized data is subjected to data compression storage to obtain stored data, specifically including:

[0076] S41: State change events and corresponding time window data are screened out based on the optimized data.

[0077] S42: When the change frequency of the state change event is greater than a preset number of times, Huffman coding is adopted for binary bit stream compression storage.

[0078] S43: When the change frequency of the state change event is stable, RLE is adopted for storage.

[0079] Specifically, the optimized data is subjected to data compression storage to obtain stored data, further including:

[0080] S44: Add device ID and working condition label to the state change event.

[0081] S45: Use RAM to store the state change events and corresponding time window data of the last 24 hours.

[0082] S46: After classifying the state change events and corresponding time window data by time / event, write them into the solid state disk using columnar storage structure.

[0083] As an optional implementation, the crane electrical control system switch value data acquisition and storage optimization method further comprises: transmitting the interrupted switch value data to the crane cloud management platform.

[0084] In a specific application, the application provides a crane electrical control system switch value data acquisition and storage optimization method, which specifically comprises the following steps:

[0085] Step 1: Switch value data acquisition optimization.

[0086] Dynamic frequency adjustment: dynamically adjust the sampling frequency according to the device operating state (such as starting, running, fault) and signal change rate. For example, the sampling frequency is increased to 100 Hz in the fault state and decreased to 10 Hz in the stable state.

[0087] Event triggering mechanism: interrupt triggering is adopted for key switches (such as emergency stop, overload alarm), high-frequency acquisition is triggered through state mutation detection (such as signal jump, logic combination event), the state change time and duration are recorded in real time, and the integrity of key data is ensured.

[0088] Step 2: Data processing optimization.

[0089] Adaptive filter de-bouncing: sliding window algorithm is adopted, and the window size is dynamically adjusted according to the signal type (such as limit signal window = 5 ms, contactor signal window = 20 ms); if the number of state jumps in the window exceeds the threshold value (default is 1), it is determined that it is dithering, and the abnormal data is discarded.

[0090] Data preprocessing: noise filtering and state logic verification are performed on the edge node to eliminate invalid data.

[0091] Step 3: Data compression storage optimization.

[0092] Event-based storage strategy: only store state change events and related time window data, reduce static signal redundancy. For example, record the time (t) of state change and the new state value (S), generate sequence (t1, S1; t2, S2;...).

[0093] Variable frequency storage: Huffman encoding is used for frequently changing segments (e.g., changes ≥3 times within 1 second), and binary bit stream compression is performed.

[0094] Tagging and indexing: Device ID and working condition tags (e.g., "overload," "emergency stop") are added to the data to support quick retrieval and analysis.

[0095] Hierarchical storage architecture:

[0096] Short-term cache layer: RAM is used to store the last 24 hours of data, supporting fast queries.

[0097] Long-term storage layer: Data is written to a solid-state drive after being categorized by time / event, using a columnar storage structure to optimize historical data retrieval efficiency.

[0098] Step 4: Data transmission and management.

[0099] Key switch quantity data (e.g., start / stop, limit, fault status) in the main hoisting, amplitude, rotation, walking, and safety protection systems of the crane are transmitted in real time through the communication module to the crane cloud management platform, enabling remote monitoring, fault warning, data backtracking, health analysis, and other functions.

[0100] The specific workflow is shown in Figure 3 .

[0101] Example 1: Data acquisition optimization.

[0102] Taking the crane hoisting mechanism as an example, three key switch quantities (overload sensor, height limit, brake status) and five ordinary signals (hoisting command, descending command, stop command, running indicator light, fan status, etc.) are configured.

[0103] Key signals: Set to interrupt trigger mode, record timestamp immediately upon state change.

[0104] Ordinary signals: Set the polling period to 100 ms during the hoisting phase (determined by the PLC running state word), and 1000 ms in other phases.

[0105] Example 2: Data compression storage.

[0106] Original data sequence (time unit: ms):

[0107] textCopy Code: t=0, S=0; t=100, S=1; t=150, S=0; t=200, S=1; t=1000, S=1.

[0108] After differential encoding: (0, 0), (100, 1), (150, 0), (200, 1), (1000, 1).

[0109] Compression processing: Huffman encoding is used for the first 4 jumps (0-200 ms), and the subsequent stable segment (200-1000 ms) is stored as (200, 1000, 1) using RLE.

[0110] Example 3: Data retrieval.

[0111] The user inputs a query condition (such as "overload alarm event on 2023-10-01"), the system locates the corresponding storage block through the time index, and returns the original data of the alarm occurrence time and duration after decompression.

[0112] As shown in Figure 4 A crane electrical control system switching value data acquisition and storage optimization device is provided, which is used to implement the crane electrical control system switching value data acquisition and storage optimization method described in any of the above, and the crane electrical control system switching value data acquisition and storage optimization device comprises a crane electrical control system, a signal acquisition module, a processing unit, a storage module, and a crane cloud management platform.

[0113] The crane electrical control system is composed of a driving device, a control device, a sensor, and an actuator, and adopts a main control PLC and a frequency converter to realize precise motor speed regulation and multi-mechanism collaborative control, and is deployed in each electrical cabinet of the crane.

[0114] The signal acquisition module communicates with the crane electrical control system through a CAN bus, and is used to acquire switching value data in the main control PLC.

[0115] The processing unit adopts a dual-core heterogeneous architecture. The processing unit comprises:

[0116] An ARM processor is used to run dynamic polling logic.

[0117] An FPGA processor is used to process interrupt triggering and real-time filtering.

[0118] The storage module comprises:

[0119] A RAM cache layer is used to store state change events and corresponding time window data in the last 24 hours.

[0120] A solid state storage layer is used to store state change events and corresponding time window data in a columnar storage structure after classification by time / event.

[0121] The crane cloud management platform is used to receive interrupted switching value data, support remote monitoring and fault early warning, and provide device health reports and abnormal data backtracking functions.

[0122] As an optional implementation, the signal acquisition module comprises:

[0123] The multi-channel optical coupling isolation input circuit is used for supporting 0-24V switching value signal acquisition.

[0124] The RC filter circuit is used for suppressing high-frequency noise. That is, the signal acquisition module integrates the multi-channel optical coupling isolation input circuit, supports 0-24V switching value signal acquisition, and is designed to resist interference: the RC filter circuit is connected in parallel at the input end to suppress high-frequency noise.

[0125] As an optional implementation, the processing unit further comprises an internal clock module for ensuring that the time stamp precision of the multi-channel data is less than or equal to a preset value. In this embodiment, the preset value is 1ms.

[0126] As an optional implementation, the storage module further comprises a power failure protection circuit for ensuring that the cache data is completely written into the storage medium in the event of sudden power failure.

[0127] Specifically, the storage module adopts a hierarchical storage design. The cache layer: the DDR3 RAM stores the data in the last 24 hours, supporting fast reading and writing; the persistent layer: the solid-state storage compresses the data, and stores the data by day (after being classified by time / event, the data is written into the solid-state disk, and a columnar storage structure is adopted); power failure protection: super capacitor power supply, ensuring that the cache data is completely written into the storage medium in the event of sudden power failure.

[0128] The application of the present application will bring the following advantages:

[0129] Data volume is reduced by more than 50%: through dynamic sampling and event compression, the storage cost is reduced.

[0130] Real-time performance is improved: the edge node preprocessing reduces the load of the central system, and the response speed is improved by 30%.

[0131] Fault tracing efficiency is improved: the labeled data supports fast query based on events, and the fault diagnosis time is shortened.

[0132] The technical features of the above embodiments can be combined in any way. In order to make the description concise, not all possible combinations of the technical features in the above embodiments are described, however, as long as the combinations of the technical features do not exist contradictory, they should be considered as the scope of the present application.

[0133] The principles and implementation modes of the present application are described by using specific examples in this paper, and the above embodiments are only used to help understand the method and its core idea of the present application; at the same time, for those skilled in the art, according to the idea of the present application, the specific implementation mode and application range will be changed. In conclusion, the content of the specification should not be understood as a limitation of the present application.

Claims

1. A crane electrical control system switch quantity data acquisition and storage optimization method, characterized in that: The crane electrical control system switch quantity data acquisition and storage optimization method includes: Obtaining the operating status of the crane electrical control system; the operating status includes: starting, running and fault; Based on the operating status, collecting switch quantity data; Performing data optimization processing on the switch quantity data to obtain optimized data; The optimized data is compressed and stored to obtain stored data.

2. The crane electrical control system switch quantity data acquisition and storage optimization method according to claim 1 is characterized in that: Based on the operating status, the switch quantity data is collected, specifically including: According to the operating status, different collection cycles are set; Determine whether the operating state is a key switch value and obtain a determination result; If the judgment result is yes, the interrupt trigger mode is adopted to read the interrupt switch value data and record the state change time and duration; If the judgment result is no, then based on the acquisition cycle, a polling cycle mode is adopted to read the switch quantity data of the polling cycle.

3. The crane electrical control system switch quantity data acquisition and storage optimization method according to claim 1 is characterized in that: Performing data optimization processing on the switch quantity data to obtain optimized data specifically includes: Adopting a sliding window algorithm to perform adaptive filtering and de-jittering on the switch quantity data to obtain de-jittered data; The de-jittered data is subjected to noise filtering and state logic verification at the edge node, invalid data is eliminated, and optimized data is obtained.

4. The crane electrical control system switch quantity data acquisition and storage optimization method according to claim 1 is characterized in that: Compressing and storing the optimized data to obtain stored data specifically includes: Based on the optimized data, filtering out state change events and corresponding time window data; When the change frequency of the state change event is greater than a preset number of times, Huffman coding is used to compress and store the event in binary bit stream; When the change frequency of the state change event is stable, RLE is used for storage.

5. The crane electrical control system switch quantity data acquisition and storage optimization method according to claim 4 is characterized in that: Compressing and storing the optimized data to obtain stored data further includes: Adding a device ID and a working condition tag to the state change event; Use RAM to store the state change events and corresponding time window data for the last 24 hours; The state change events and the corresponding time window data are classified by time / event and written into a solid-state hard disk using a columnar storage structure.

6. The crane electrical control system switch quantity data acquisition and storage optimization method according to claim 1 is characterized in that: The crane electrical control system switch quantity data acquisition and storage optimization method further includes: Transmit the interrupted switch data to the crane cloud management platform.

7. A device for collecting and storing switching data of a crane electrical control system, characterized in that: The device for collecting and storing switching value data of a crane electrical control system is used to implement the method for collecting and storing switching value data of a crane electrical control system according to any one of claims 1 to 6. The device for collecting and storing switching value data of a crane electrical control system comprises: a crane electrical control system, a signal acquisition module, a processing unit, a storage module, and a crane cloud management platform. The crane electrical control system consists of a drive device, a control device, sensors, and actuators. It uses a master PLC and a frequency converter to achieve precise motor speed regulation and multi-mechanism coordinated control, and is deployed in each electrical cabinet of the crane. The signal acquisition module communicates with the crane electrical control system via the CAN bus and is used to collect switch value data in the main control PLC; The processing unit includes: ARM processor for running dynamic polling logic; FPGA processor, used to handle interrupt triggering and real-time filtering; The storage module includes: RAM cache layer, used to store the state change events and corresponding time window data of the last 24 hours; The solid-state storage layer is used to classify state change events and corresponding time window data by time / event and store them in a columnar storage structure; The crane cloud management platform is used to receive interrupted switch quantity data, support remote monitoring and fault warning, and provide equipment health report and abnormal data backtracking functions.

8. The device for collecting, storing and optimizing switch quantity data of a crane electrical control system according to claim 7 is characterized in that: The signal acquisition module includes: Multi-channel optocoupler isolation input circuit to support 0-24V switch signal acquisition; RC filter circuit is used to suppress high-frequency noise.

9. The device for collecting, storing and optimizing switch quantity data of a crane electrical control system according to claim 7, characterized in that: The processing unit further includes: The internal clock module is used to ensure that the timestamp accuracy of multi-channel data is less than or equal to the preset value.

10. The device for collecting, storing and optimizing switch quantity data of a crane electrical control system according to claim 7, characterized in that: The storage module further includes: The power-off protection circuit is used to ensure that cached data is completely written to the storage medium in the event of a sudden power outage.

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