Plant process environment monitoring system

Abstract

The invention provides a plant process environment monitoring system, which realizes information intensification, facilitates unified management and scheduling, is reliably used for guaranteeing production safety, and greatly enhances the convenience degree of information management. The system comprises a plurality of groups of lower computer environment parameter acquisition and processing modules, which comprise a plurality of workshop environment parameter acquisition modules and a plurality of atmospheric environment parameter acquisition modules, and each group of lower computer environment parameter acquisition and processing module comprises a plurality of corresponding environment parameter sensors, a buzzer alarm and a control module responsible for processing data, the upper computer monitoring module comprises at least one upper computer and an Internet of Things module, each upper computer is arranged in the corresponding control center, and the Internet of Things module performs data transmission through the switch.

Description

Technical Field

[0001] This invention relates to the technical field of environmental monitoring, specifically to a factory process environment monitoring system. Background Technology

[0002] In a factory production environment, the personal safety of production personnel and the quality and purity of the products produced are two particularly important factors. Ensuring these two factors is an effective prerequisite for guaranteeing safe and stable production. However, in actual production environments, there are issues such as changes in factory temperature and humidity, and pollution from harmful gases and particulate matter in the atmosphere, which may endanger personal safety and product quality, thereby affecting the production process. Therefore, monitoring the factory process environment is of paramount importance.

[0003] Currently, existing factory environment monitoring methods mainly target temperature, humidity, and specific harmful gases, but these are relatively independent and cannot be monitored uniformly. Secondly, these methods only provide real-time data monitoring and lack data recording and storage capabilities, failing to provide historical data and data curves for professional querying and analysis. Furthermore, these methods can only obtain data by viewing instruments on-site, and cannot remotely and centrally monitor data through multiple methods, causing numerous inconveniences to the production process. To address these issues, there is an urgent need to develop a factory process environment monitoring system that can reliably ensure the personal safety of production personnel and the quality and purity of the manufactured products. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a factory process environment monitoring system that achieves information centralization, facilitates unified management and scheduling, reliably ensures production safety, and greatly enhances the convenience of information management.

[0005] A factory process environment monitoring system, characterized in that it comprises: Several sets of lower-level environmental parameter acquisition and processing modules are included, comprising several indoor environmental parameter acquisition modules and several atmospheric environmental parameter acquisition modules. Each set of lower-level environmental parameter acquisition and processing modules includes corresponding environmental parameter sensors, a buzzer alarm, and a control module responsible for processing data. And a host computer monitoring module, which includes at least one host computer and an Internet of Things (IoT) module. Each host computer is set up in a corresponding control center, and the IoT module transmits data through a switch. Each control center is independently equipped with a buzzer alarm to alert the lower-level machine of an alarm. Several sets of lower-level machine environmental parameter acquisition and processing modules are responsible for monitoring environmental parameters and sending the monitoring data to the corresponding control modules. The control module has communication and logic processing functions. It collects and processes the data collected from the corresponding environmental parameter sensors, and then sends the processed data to each host computer monitoring module through the switch via the ModbusTCP communication protocol. The buzzer alarm is used to receive alarm signals from the control module and to provide buzzer and flashing alarm reminders to the site and control center. The host computer receives data and signals from various control modules and displays the relevant data in real time.

[0006] Its further features are The host computer stores relevant data to form historical data and historical data curves, and displays alarm information; the host computer can manually or automatically set alarm values ​​for relevant environmental parameters. The IoT module simultaneously receives data and signals from various control modules and uploads them to the cloud platform in a timely manner, where the data is displayed and stored. For the indoor environment of the factory, the sensor types include temperature and humidity sensors, as well as sensors for detecting harmful gases such as chlorine and hydrogen cyanide; for the atmospheric environment, the sensors include temperature and humidity sensors, wind speed and direction sensors, ozone sensors, sensors for detecting harmful gases such as carbon dioxide, and sensors for detecting particulate pollutants. The corresponding environmental parameter sensors communicate with the control module via an RS-485 hub or an analog input module through a communication cable. The IoT control module connects to Ethernet and obtains data from various control modules through the Modbus TCP communication protocol. Data on the cloud platform can be viewed through authorized mobile devices or computer web pages. Alarm information is a graphic alarm, which is displayed on the alarm information page of the host computer; the buzzer alarm is an audible and visual alarm, which is activated and alerted by buzzers at the field and control center. Both graphic alarms and audible and visual alarms are triggered by alarm signals. The host computer settings page sets the first and second level thresholds for various environmental parameters based on the plant's internal and atmospheric environments. If a value exceeds the threshold, the control module will simultaneously send a corresponding alarm signal to both the buzzer and the host computer. The host computer will record the alarm signal and pop up a message window to remind the user, while the buzzer will remind the user by flashing its beeping sound.

[0007] Compared with existing technologies, the beneficial effects of this invention are as follows: (1) The control module sends all data from various regions and environmental monitoring sensors to the host computer in the control center. The host computer is used to centrally display all environmental parameter data. Multiple control centers can be configured to display the data of the corresponding regions, thus achieving centralized display of various different data, realizing information aggregation, and facilitating unified management and scheduling. (2) By realizing the unified monitoring of real-time data display, historical data and historical curves, alarm content and other information of various regions on the host computer, it is convenient for managers to perform various data analysis and prediction. At the same time, the alarm content is accurate and comprehensive, enabling operators to promptly check the fault point and avoid possible personal safety and product damage, thus ensuring production safety to a certain extent. (3) It can view the data of various environmental parameters through a host computer, web page, mobile phone, etc. Managers are not limited to working hours and factory environment, and can view them anytime and anywhere, which greatly enhances the convenience of information management. Attached Figure Description

[0008] Figure 1 This is a communication network diagram of the factory process environment monitoring system of the present invention; Figure 2 This is an alarm control diagram for the factory process environment monitoring system of the present invention. Detailed Implementation

[0009] A factory process environment monitoring system, see Figure 1 and Figure 2 It includes several host computers, multiple control modules, and various sensors; Various sensors are deployed in places where environmental monitoring is required, and are mainly responsible for collecting data at a specific location. The sensors include temperature and humidity sensors, harmful gas sensors, and particulate matter sensors. The control module is responsible for centrally summarizing and processing the data collected by the sensors in a divided area. It mainly obtains various data from the sensors through analog input modules and RS-485 hubs. The host computer uses Modbus TCP communication via RJ45 network cable to connect with the control modules of each area through a switch, thereby obtaining environmental data from all areas, storing and displaying the corresponding environmental data, and triggering alarms and interface reminders if data exceeds the limit, so that monitoring personnel can promptly notify the corresponding plant operators to take necessary actions.

[0010] In practice, sensors are placed in specific locations within the factory to monitor the environment inside the factory and in the atmosphere. Inside the factory, sensors primarily used are those for temperature, humidity, and substances closely related to and affecting production, such as chlorine and hydrogen cyanide. The corresponding data is collected and displayed to prevent harm to production personnel and product quality. For atmospheric data, the system mainly collects data on atmospheric temperature and humidity, wind speed and direction, harmful gases such as sulfur dioxide and ozone, and particulate matter such as PM2.5 and PM10, in order to provide early warnings of meteorological disasters. The aforementioned sensors input various environmental parameters to the corresponding control modules via input modules and RS-485 hubs.

[0011] Each factory area requiring environmental monitoring is equipped with a control module. The control module has communication and logic processing functions, which is used to collect and process data collected from sensors in various locations in the area, and send the processed data and alarm signals to the host computer via Ethernet through the ModbusTCP communication protocol.

[0012] Each control center is equipped with a host computer to monitor plant environmental data. By acquiring data from control modules distributed in various areas, the host computer displays real-time temperature and humidity, real-time harmful gas content, real-time air pollutant data, etc. for each area. Historical data of the above parameters are stored for a certain period of time for relevant personnel to query and analyze later. At the same time, the host computer implements the historical curve function of each parameter to more intuitively show the historical trend of parameter data.

[0013] In the plant process environment monitoring system, control centers of different levels in different areas are granted corresponding permissions. Each area's control center can only view environmental parameter data and modify alarm thresholds for its own area, while the central control center can view environmental parameter data and alarm information for all areas.

[0014] A buzzer alarm is added to each host computer. The alarm device receives output signals from multiple control modules and displays real-time alarm information on the host computer. It also allows setting corresponding first-level and second-level alarm thresholds for each parameter. If any parameter in the acquired data exceeds this threshold, the buzzer alarm sounds and displays the corresponding alarm level on the host computer. At this point, control center personnel can determine the area where the alarm occurred and the parameter exceeding the limit based on the alarm information, thus notifying the operators in that area to take appropriate action.

[0015] The factory process environment monitoring system also includes an IoT module for real-time monitoring of various environmental parameters. The IoT module communicates with each control module via the Modbus TCP protocol to acquire real-time data for each parameter. This data is then uploaded to a cloud platform. Authorized personnel can view real-time environmental parameter data for each area via mobile phone or web browser. Alarm information can be sent to authorized mobile phone numbers via SMS or telephone.

[0016] In a specific embodiment, the host computer is distributed in each control center and receives data from the control module through the switch via the Modbus TCP protocol. It displays and records the data, graphic alarms, operation logs, and historical data of each environmental parameter acquisition and processing module, and sets alarm thresholds for each environmental parameter. The historical data can be saved for a set number of days, specifically 180 days. The IoT module can also acquire data from the control module and upload the selected data to the cloud server. Specific environmental parameters can be viewed through a web page and a mobile app. At the same time, it can be set to send reminders via mobile phone calls and SMS when a parameter exceeds a set threshold. The buzzer alarm receives alarm signals from the control module and is placed in the factory production environment and control center to broadcast alarm information on environmental parameters in each area. The graphic and text alarm information from the host computer can accurately describe the type of alarm and other alarm information, which can help operators quickly and accurately find and troubleshoot faults in a timely manner, thus improving the reliability of system operation.

[0017] Compared with existing technologies, the beneficial effects of this invention are as follows: (1). The control module sends all data from various environmental monitoring sensors in each area to the host computer in the control center. The host computer is used to centrally display all environmental parameter data. Multiple host computers can be configured in multiple control centers to display data from the corresponding areas, thus achieving centralized display of various data, realizing information aggregation, and facilitating unified management and scheduling. (2). By realizing the unified monitoring of real-time data display, historical data and historical curves, alarm content and other information of various regions on the host computer, it is convenient for managers to perform various data analysis and prediction. At the same time, the alarm content is accurate and comprehensive, enabling operators to promptly check the fault point and avoid possible personal safety and product damage, thus ensuring production safety to a certain extent. (3) The data of various environmental parameters can be viewed through a host computer, web page, mobile phone, etc. Managers are not limited to working hours and factory environment, and can view them anytime and anywhere, which greatly enhances the convenience of information management.

[0018] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0019] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A factory process environment monitoring system, characterized in that, It includes: Several sets of lower-level environmental parameter acquisition and processing modules are included, comprising several indoor environmental parameter acquisition modules and several atmospheric environmental parameter acquisition modules. Each set of lower-level environmental parameter acquisition and processing modules includes corresponding environmental parameter sensors, a buzzer alarm, and a control module responsible for processing data. And a host computer monitoring module, which includes at least one host computer and an Internet of Things (IoT) module. Each host computer is set up in a corresponding control center, and the IoT module transmits data through a switch. Each control center is independently equipped with a buzzer alarm to alert the lower-level machine of an alarm. Several sets of lower-level machine environmental parameter acquisition and processing modules are responsible for monitoring environmental parameters and sending the monitoring data to the corresponding control modules. The control module has communication and logic processing functions. It collects and processes the data collected from the corresponding environmental parameter sensors, and then sends the processed data to each host computer monitoring module through the switch via the ModbusTCP communication protocol. The buzzer alarm is used to receive alarm signals from the control module and to provide buzzer and flashing alarm reminders to the site and control center. The host computer receives data and signals from various control modules and displays the relevant data in real time.

2. The factory process environment monitoring system according to claim 1, characterized in that: The host computer stores relevant data to form historical data and historical data curves, and displays alarm information; the host computer can manually or automatically set alarm values ​​for relevant environmental parameters.

3. The factory process environment monitoring system according to claim 1, characterized in that: The IoT module simultaneously receives data and signals from various control modules and uploads them to the cloud platform in a timely manner, where the data is displayed and stored.

4. The factory process environment monitoring system according to claim 1, characterized in that: For the indoor environment of the factory, the sensor types include temperature and humidity sensors, as well as sensors for detecting harmful gases such as chlorine and hydrogen cyanide; for the atmospheric environment, the sensors include temperature and humidity sensors, wind speed and direction sensors, ozone sensors, sensors for detecting harmful gases such as carbon dioxide, and sensors for detecting particulate pollutants.

5. The factory process environment monitoring system according to claim 1, characterized in that: The corresponding environmental parameter sensors communicate with the control module via an RS-485 hub or an analog input module through a communication cable.

6. The factory process environment monitoring system according to claim 1, characterized in that: The IoT control module connects to Ethernet and obtains data from various control modules through the Modbus TCP communication protocol. Data on the cloud platform can be viewed through authorized mobile devices or computer web pages.

7. The factory process environment monitoring system according to claim 1, characterized in that: Alarm information is classified as graphic alarm, and is displayed on the alarm information page of the host computer; buzzer alarm is classified as audible and visual alarm, and is activated and alerted by buzzer alarms at the site and control center. Both graphic alarm and audible and visual alarm are triggered by alarm signals.

8. The factory process environment monitoring system according to claim 1, characterized in that: The host computer settings page sets the first and second level thresholds for various environmental parameters based on the plant's internal and atmospheric environments. If a value exceeds the threshold, the control module will simultaneously send a corresponding alarm signal to both the buzzer and the host computer. The host computer will record the alarm signal and pop up a message window to remind the user, while the buzzer will remind the user by flashing its beeping sound.

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