Mine sensor collaborative OTA upgrading and safe backspacing method and system

Abstract

The invention relates to a mine sensor collaborative OTA upgrading and safe backspacing method and system in the technical field of mine Internet of Things and intelligent sensing. The operation and maintenance terminal initiates an upgrading task, and the firmware server issues target firmware to the substation main upgrading node; the substation main upgrade node receives the firmware package, performs integrity verification and updates itself; the main upgrading node broadcasts upgrading tasks to the collaborative nodes and distributes data blocks; the collaborative node identifies a lower-level sensor type, executes model filtering, and only upgrades a target model; in the upgrading process, each node reports a state to the operation and maintenance terminal regularly; and after all the sensors are upgraded, the system automatically generates an upgrading report and archives the upgrading report. According to the invention, cross-regional collaboration is realized through the substation network, and the efficiency is improved by several times; huge bandwidth overhead and time consumption caused by independently upgrading each underground sensor by a ground server are avoided; global upgrading is achieved through one-time operation, and manual intervention is greatly reduced.

Description

Technical Field

[0001] This invention relates to the field of mining IoT and intelligent sensing technology, and in particular to a multi-level collaborative OTA (Over-The-Air) firmware upgrade and secure rollback method and system suitable for complex network environments in mines, supporting hybrid collaboration between substation networks and Bluetooth. Background Technology

[0002] In mining IoT systems, sensors are used to monitor gas concentration, temperature and humidity, and equipment operating status. These devices are numerous, widely distributed, and operate in enclosed environments with significant signal interference. Traditional upgrade methods suffer from the following problems:

[0003] (1) Low upgrade efficiency: Existing OTA upgrades rely on terminals connecting to devices one by one via Bluetooth, which is time-consuming and cannot be upgraded quickly in batches;

[0004] (2) Network diversity limitation: There are wired / wireless networks in the mine, but the existing upgrade plan cannot combine the substation network and Bluetooth to work together, resulting in insufficient resource utilization;

[0005] (3) Signal blind zone problem: The tunnel structure is complex and some sensors are located in the Bluetooth blind zone, resulting in interruption and failure;

[0006] (4) High safety risks: In the mining environment, once gas or dust exceeds the limit during the upgrade process, the equipment must be restored to monitoring immediately, but traditional solutions lack emergency downgrade strategies. Summary of the Invention

[0007] This invention aims to solve the efficiency, stability, and security issues in the OTA upgrade process of mine sensors, specifically including:

[0008] How to leverage substation networks and Bluetooth to achieve multi-level collaborative upgrades and significantly improve efficiency;

[0009] How to ensure upgrade completion rate in the event of network interruption or signal dead zone;

[0010] How to quickly interrupt and revert to secure firmware during an emergency security incident to ensure monitoring continuity.

[0011] To address the aforementioned technical problems, this invention provides a method for coordinated OTA upgrades and secure rollbacks of mine sensors, comprising the following steps;

[0012] (1) The maintenance terminal initiates an upgrade task, and the firmware server sends the target firmware to the substation master upgrade node;

[0013] (2) The substation master upgrade node receives the firmware package, performs integrity verification, and updates itself;

[0014] (3) The primary upgrade node broadcasts the upgrade task to the cooperating nodes and distributes data blocks;

[0015] (4) The collaborative node identifies the type of the lower-level sensor, performs model filtering, and upgrades only the target model;

[0016] (5) During the upgrade process, each node shall periodically report its status to the operation and maintenance terminal;

[0017] (6) Once all sensors have been upgraded, the system will automatically generate and archive an upgrade report.

[0018] To achieve multi-level collaborative upgrades, after the maintenance terminal initiates an upgrade task, it checks network conditions, selects the corresponding collaborative upgrade mode based on different network conditions, and sets priorities. The collaborative upgrade modes are as follows:

[0019] Mode 1—Sub-site Network Collaborative Upgrade:

[0020] When there is a network connection between substations, after the sensor under a certain substation completes the upgrade, the substation will synchronize the firmware to other substations through the network, and the other substations will then distribute it to the same type of sensors within their jurisdiction, realizing batch upgrades across the entire mine.

[0021] Mode 2—Partial Bluetooth Collaboration Upgrade:

[0022] When the substation network is down, but Bluetooth signals between sensors are still available, the upgraded sensors can transmit the firmware to surrounding sensors of the same model via Bluetooth diffusion, thus achieving regional collaborative upgrades.

[0023] Mode 3 - Single Node Upgrade:

[0024] When only a single sensor can be connected via Bluetooth on the terminal, upgrade them one by one using the traditional OTA method;

[0025] To ensure overall efficiency, the multi-level collaborative upgrade scheduling logic allows the system to automatically select the optimal mode based on the substation network status and Bluetooth topology.

[0026] To ensure security event-driven interruption and rollback, security indicators are monitored in real time during the upgrade process. If limits are exceeded or an emergency stop command is received, the upgrade is immediately interrupted, and the system rolls back to the old firmware to ensure the operation of security functions. The interruption point is recorded, and the upgrade can continue after the security is cleared.

[0027] The present invention also provides a mine sensor collaborative OTA upgrade and safe rollback system for the above-mentioned mine sensor collaborative OTA upgrade and safe rollback method, including a ground control layer, an underground network layer, a substation control layer and a sensor execution layer, wherein the ground control layer, the underground network layer and the sensor execution layer are respectively connected to the substation control layer.

[0028] Furthermore, the ground control layer includes an operation and maintenance terminal and a firmware server. The operation and maintenance terminal is used for operation and maintenance personnel to interact with the system and can monitor the upgrade status of each substation and sensor in real time. The firmware server is used to store firmware version files of various sensors and control nodes and provides version management, upgrade package distribution and verification functions.

[0029] Furthermore, the substation control layer consists of multiple substation nodes. Each substation node includes a main upgrade node and several cooperative nodes. The main upgrade node and the firmware server are connected via a TCP / IP network. The cooperative nodes receive firmware packages from the main upgrade node and further distribute them to their subordinate sensors.

[0030] Furthermore, the sensor execution layer includes multiple sensor devices of different models, each of which can independently report its own version status.

[0031] In summary, the present invention has the following beneficial effects:

[0032] (1) Significantly improved upgrade efficiency: Cross-regional collaboration is achieved through the substation network, improving efficiency several times over;

[0033] (2) High efficiency and time saving: It avoids the huge bandwidth overhead and time consumption of upgrading each downhole sensor individually by the ground server;

[0034] (3) Automated batch operations: One operation, global upgrade, greatly reducing manual intervention;

[0035] (4) Enhanced safety: The safety incident rollback mechanism ensures uninterrupted mine safety monitoring;

[0036] (5) Highly adaptable: It can automatically switch upgrade modes according to the on-site network conditions. Attached Figure Description

[0037] Figure 1 This is a structural block diagram of the mining sensor collaborative OTA upgrade and safe rollback system of the present invention;

[0038] Figure 2 This is a flowchart of the mining sensor collaborative OTA upgrade and safe rollback method of the present invention;

[0039] Figure 3 This is a flowchart of the partial Bluetooth collaborative upgrade of the present invention. Detailed Implementation

[0040] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby providing a clearer and more explicit definition of the scope of protection of the present invention.

[0041] like Figure 1 The system shown is a mine sensor collaborative OTA upgrade and safety rollback system, which includes a ground control layer, an underground network layer, a substation control layer and a sensor execution layer. The ground control layer, the underground network layer and the sensor execution layer are respectively connected to the substation control layer.

[0042] I. Ground Control Layer

[0043] The ground control layer includes operation and maintenance terminals and firmware servers.

[0044] Firmware servers are used to store firmware version files for various sensors and control nodes, and provide version management, upgrade package distribution and verification functions.

[0045] The firmware server communicates with the primary upgrade node in the lower-level substation control layer via the network backbone.

[0046] The firmware server can distribute different target firmware versions based on information such as sensor type and substation number.

[0047] The operation and maintenance terminal is used for operation and maintenance personnel to interact with the system and can monitor the upgrade status of each substation and sensor in real time.

[0048] The operation and maintenance terminal obtains the version status information of devices at each layer through secure communication protocols (such as HTTPS or MQTT).

[0049] The operation and maintenance terminal can issue upgrade commands, pause commands, or rollback commands to specific nodes.

[0050] II. Substation Control Layer

[0051] The substation control layer is deployed underground or at the distributed control unit and consists of multiple substation nodes. Each substation node includes a main upgrade node and several cooperating nodes.

[0052] The main upgrade node is responsible for receiving upgrade packages from the ground firmware server, verifying their integrity, and distributing the upgrade data to collaborative nodes within the same substation or adjacent substations.

[0053] The primary upgrade node and the firmware server are connected via a TCP / IP network.

[0054] The upgrade status of the primary upgrade node can include "not started", "transferring", "completed", etc.

[0055] Collaborating nodes: Used to share the upgrade data transmission and execution tasks of the master node, thereby improving the overall upgrade efficiency.

[0056] The collaborating node receives the firmware package from the master node and then distributes it to its subordinate sensors.

[0057] Progress synchronization and version confirmation can be performed between the collaborative nodes.

[0058] Once the master node upgrade is complete, the collaborating nodes enter the "transferring" or "synchronizing" state to ensure version consistency.

[0059] Inter-substation communication: Adjacent substations can be connected via industrial Ethernet or fiber optic ring network to achieve redundant data transmission and cross-substation upgrades.

[0060] The system supports the collaborative node taking over the upgrade task when the master node fails.

[0061] III. Sensor Execution Layer

[0062] The sensor execution layer contains multiple sensor devices of different models (such as Type A, Type B, etc.), and each sensor can independently report its own version status.

[0063] Upgrade strategy:

[0064] Once the cooperating node confirms that the sensor model is the target model (e.g., Type A), it will issue the corresponding firmware version.

[0065] If the sensor model does not match (e.g., Type B, not the target model), the system will automatically skip the device and enter the model filtering state.

[0066] Upgrade process:

[0067] The cooperating nodes will send upgrade data blocks to the sensors in batches.

[0068] After the sensor completes firmware writing and verification, it reports an "upgrade complete" status.

[0069] If the sensor is running or environmental conditions are not met (such as low battery), the upgrade command can be temporarily stored and executed automatically when the conditions are met.

[0070] Version control:

[0071] Each sensor stores version information (e.g., v1.5, v2.1) and periodically reports it to the ground control layer through substation nodes.

[0072] The system can automatically determine whether an upgrade is needed based on version number differences.

[0073] Combination Figure 2 As shown, the present invention provides a method for coordinated OTA upgrade and safe rollback of mine sensors, including the following steps;

[0074] (1) The maintenance terminal initiates an upgrade task, and the firmware server sends the target firmware to the substation master upgrade node;

[0075] (2) The substation master upgrade node receives the firmware package, performs integrity verification, and updates itself;

[0076] (3) The primary upgrade node broadcasts the upgrade task to the cooperating nodes and distributes data blocks;

[0077] (4) The collaborative node identifies the type of the lower-level sensor, performs model filtering, and upgrades only the target model;

[0078] (5) During the upgrade process, each node shall periodically report its status to the operation and maintenance terminal;

[0079] (6) Once all sensors have been upgraded, the system will automatically generate and archive an upgrade report.

[0080] When the maintenance terminal initiates an upgrade task, it checks the network conditions, selects the corresponding collaborative upgrade mode based on the different network conditions, and sets the priority; the collaborative upgrade modes are as follows:

[0081] Mode 1—Sub-site Network Collaborative Upgrade (Highest Priority):

[0082] When there is a network connection between substations, after the sensor under a certain substation completes the upgrade, the substation will synchronize the firmware to other substations through the network, and the other substations will then distribute it to the same type of sensors within their jurisdiction, realizing batch upgrades across the entire mine.

[0083] Mode 2—Partial Bluetooth Collaboration Upgrade:

[0084] When the substation network is down, but Bluetooth signals between sensors are still available, the upgraded sensors can transmit the firmware to surrounding sensors of the same model via Bluetooth diffusion, thus achieving regional collaborative upgrades.

[0085] Mode 3 - Single Node Upgrade:

[0086] When only a single sensor can be connected via Bluetooth on the terminal, upgrade them one by one using the traditional OTA method;

[0087] The multi-level collaborative upgrade scheduling logic allows the system to automatically select the optimal mode based on the substation network status and Bluetooth topology, ensuring overall efficiency.

[0088] During the upgrade process, the system monitors safety indicators such as gas concentration and dust in real time. If the limits are exceeded or an emergency shutdown command is received, the upgrade is immediately interrupted, and the system is rolled back to the old firmware to ensure the operation of safety functions. The interruption point is recorded, and the upgrade can continue after the interruption is safely resolved.

[0089] The process for partial Bluetooth collaborative upgrades is as follows: Figure 3 As shown:

[0090] Step S1: Scan and connect via Bluetooth

[0091] First, enable Bluetooth on your device and perform a Bluetooth scan to find nearby connectable devices. Once a target device is detected, send a connection request to it according to the Bluetooth communication protocol. After the target device responds, a stable Bluetooth connection is established. This step is fundamental for subsequent firmware upgrades, ensuring data transfer between devices.

[0092] Step S2: Version Comparison

[0093] After the Bluetooth connection is established, the current firmware version information of the target device is obtained, and the latest remote firmware version information is also retrieved from a remote server (or a specified version storage location). Then, the current version and the remote version are compared:

[0094] If the current version is greater than or equal to the remote version, it means that the device's current firmware version is already the latest or does not need to be updated. The "No upgrade required, prompt user" operation is executed, and then the process ends.

[0095] If the current version is lower than the remote version, it means that the device needs to be upgraded with firmware. At this time, the retransmission process will begin to prepare to transmit the new firmware data.

[0096] Step S3: Retransmission and Transmission Monitoring

[0097] When an upgrade is determined to be needed (current version < remote version), the transfer of new firmware data from the remote server to the target device begins. During the transfer, the system monitors in real time for any interruptions.

[0098] If the transmission is interrupted, perform the "Record Breakpoint" operation to record the data position and other relevant information when the transmission was interrupted. Then return to the "Retransmit" step to continue transmitting firmware data from the recorded breakpoint position to ensure that the firmware data can be transmitted completely.

[0099] If the transmission is uninterrupted, the "integrity verification" step will begin after the firmware data transmission is complete.

[0100] Step S4: Integrity Verification

[0101] Integrity verification is performed on the transmitted firmware data. Verification methods may include calculating the hash value of the firmware data and comparing it with the correct hash value provided by the remote server (the specific verification algorithm can be selected according to actual needs).

[0102] If the verification fails, it means that the transmitted firmware data is incorrect or incomplete. In this case, perform the "retransmit" operation to retransmit the firmware data to ensure that complete and correct firmware data is obtained.

[0103] If the verification is successful, it means that the transmitted firmware data is complete and correct. At this point, proceed to the "Replace Firmware and Reboot" step.

[0104] Step S5: Replace firmware and reboot

[0105] The new firmware data, which has passed integrity verification, replaces the original firmware data on the target device. After replacement, the target device is restarted to make the new firmware effective. After restarting, the firmware upgrade process ends, and a "Upgrade Complete" message is displayed.

[0106] By following the steps above, reliable firmware upgrades for Bluetooth-based devices can be achieved. During transmission, potential transmission interruptions can be addressed, and the accuracy and integrity of firmware upgrades can be ensured through breakpoint resumption and data verification.

[0107] This invention allows a single firmware upgrade to be applied to all target sensors underground in the mine. In special cases where the upgrade fails to reach the sensors, manual access to the vicinity of the sensors and Bluetooth upgrade can be performed, avoiding the need for traditional methods that require removing the sensors and re-flashing the firmware. The upgrade process does not affect normal sensor monitoring functions, and the upgrade process can be automatically stopped in the event of a dangerous incident.

[0108] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape, principle and application direction of this application should be covered within the scope of protection of this application.

Claims

1. A method for coordinated OTA upgrades and safe rollback of mine sensors, characterized in that, Includes the following steps; (1) The maintenance terminal initiates an upgrade task, and the firmware server sends the target firmware to the substation master upgrade node; (2) The substation master upgrade node receives the firmware package, performs integrity verification, and updates itself; (3) The primary upgrade node broadcasts the upgrade task to the cooperating nodes and distributes data blocks; (4) The collaborative node identifies the type of the lower-level sensor, performs model filtering, and upgrades only the target model; (5) During the upgrade process, each node shall periodically report its status to the operation and maintenance terminal; (6) Once all sensors have been upgraded, the system will automatically generate and archive an upgrade report.

2. The method for coordinated OTA upgrade and safe rollback of mine sensors according to claim 1, characterized in that: After the maintenance terminal initiates an upgrade task, it checks the network conditions, selects the corresponding collaborative upgrade mode based on the different network conditions, and sets the priority; the collaborative upgrade modes are as follows: Mode 1—Sub-site Network Collaborative Upgrade: When there is a network connection between substations, after the sensor under a certain substation completes the upgrade, the substation will synchronize the firmware to other substations through the network, and the other substations will then distribute it to the same type of sensors within their jurisdiction, realizing batch upgrades across the entire mine. Mode 2—Partial Bluetooth Collaboration Upgrade: When the substation network is down, but Bluetooth signals between sensors are still available, the upgraded sensors can transmit the firmware to surrounding sensors of the same model via Bluetooth diffusion, thus achieving regional collaborative upgrades. Mode 3 - Single Node Upgrade: When only a single sensor can be connected via Bluetooth on the terminal, upgrades are performed one by one using the traditional OTA method.

3. The method for coordinated OTA upgrade and safe rollback of mine sensors according to claim 2, characterized in that: The scheduling logic for multi-level collaborative upgrades is that the system automatically selects the optimal mode based on the substation network status and Bluetooth topology.

4. The method for coordinated OTA upgrade and safe rollback of mine sensors according to claim 3, characterized in that: During the upgrade process, security indicators are monitored in real time. If limits are exceeded or an emergency stop command is received, the upgrade is immediately interrupted, and the system is rolled back to the old firmware to ensure the operation of security functions. The interruption point is recorded, and the upgrade can continue after the security is cleared.

5. A mine sensor collaborative OTA upgrade and safety rollback system, used in the mine sensor collaborative OTA upgrade and safety rollback method as described in any one of claims 1-4, characterized in that: It includes a surface control layer, a downhole network layer, a substation control layer, and a sensor execution layer, wherein the surface control layer, the downhole network layer, and the sensor execution layer are respectively connected to the substation control layer.

6. The mine sensor collaborative OTA upgrade and safety rollback system according to claim 5, characterized in that: The ground control layer includes an operation and maintenance terminal and a firmware server. The operation and maintenance terminal is used for operation and maintenance personnel to interact with the system and can monitor the upgrade status of each substation and sensor in real time. The firmware server is used to store firmware version files of various sensors and control nodes and provides version management, upgrade package distribution and verification functions.

7. The mine sensor collaborative OTA upgrade and safety rollback system according to claim 6, characterized in that: The substation control layer consists of multiple substation nodes. Each substation node includes a main upgrade node and several cooperative nodes. The main upgrade node and the firmware server are connected via a TCP / IP network. The cooperative nodes receive firmware packets from the main upgrade node and further distribute them to their subordinate sensors.

8. The mine sensor collaborative OTA upgrade and safety rollback system according to claim 7, characterized in that: The sensor execution layer includes multiple sensor devices of different models, and each sensor can independently report its own version status.

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