Fixed-person management system based on PLC + RFID

Abstract

The invention relates to a fixed-person management system based on PLC + RFID. The system comprises an upper computer, a high-frequency RFID card writer, a main controller, an industrial switch, a distributed controller, a pedestrian barrier gate, a high-frequency card reader, a grating, a vehicle barrier gate, an ultrahigh-frequency card reader, an LED screen and an audible and visual alarm, the upper computer is connected with the high-frequency RFID card writer through a USB data line, and the upper computer is connected with the main controller through the Ethernet. The main controller and the distributed controller are connected to the industrial switch through the Ethernet, the pedestrian barrier gate, the vehicle barrier gate and the audible and visual alarm are connected to the digital quantity output end of the distributed controller through signal lines, and the grating and the audible and visual alarm are connected to the digital quantity input end of the distributed controller through signal lines. The high-frequency card reader and the ultrahigh-frequency card reader are connected to the distributed controller through an RS485 bus, and the LED screen is connected to the distributed controller through the Ethernet. The system has high stability, safety and expandability, and can meet the requirement for fixed-person management of most dangerous places.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, and more specifically to a staffing management system based on PLC+RFID. Background Technology

[0002] Manufacturing and other hazardous industries are typically characterized by labor intensity, complex production processes, and high safety risks. Overstaffing and exceeding capacity often lead to loss of control over on-site management and violations of regulations. Once a production accident occurs, it not only causes huge economic losses to the enterprise but also seriously affects the safety of employees and social stability. Currently, the state is continuously strengthening its supervision of safety production in these industries, requiring enterprises to strictly abide by safety production laws and regulations and establish sound safety production management systems. Therefore, manufacturing and other hazardous industries urgently need a staffing management system to effectively control the number of personnel and vehicles on the work site, avoid safety hazards caused by overstaffing, and simultaneously record the entry and exit of personnel and vehicles from the workshop, thereby improving production efficiency and ensuring employee safety.

[0003] Currently, most manufacturing and other hazardous industry production areas are large, and for ease of management, entrances and exits are relatively centralized. Staffing management still relies on traditional methods, such as access control registration. Access control registration is highly susceptible to subjective human factors, resulting in low management efficiency. The RFID-based real-time staffing management system for industrial explosives production (publication number CN203573331U) uses high-frequency RFID for entrance and exit identification and ultra-high-frequency RFID readers for real-time on-site monitoring. This RFID-based staffing management system is suitable for smaller production sites, and identification, access control, and counting are controlled by upper and lower level computers. However, its stability is poor in harsh production environments, posing certain safety hazards. Chinese patent CN215068386U describes a non-contact staffing management and monitoring device that uses four cameras deployed at entrances and exits for staffing: two for counting and two for identification. This non-contact staffing management and monitoring device's camera identification technology lacks access control capabilities and cannot achieve substantial staffing control. In hazardous chemical production sites, workers wear full-body protective clothing and masks, making camera identification impossible. In addition, the recognition camera is affected by factors such as weather and dust, resulting in large counting errors. Summary of the Invention

[0004] To address the aforementioned technical issues, this invention proposes a PLC+RFID-based personnel management system. This system effectively solves the problems of low efficiency and poor control in existing manufacturing enterprises' management of personnel and vehicle access through access control registration. It improves the enterprise's safety management level and efficiency, and reduces the enterprise's human resource costs.

[0005] To address the aforementioned technical problems, one objective of this invention is to provide a PLC+RFID-based staffing management system. This system includes a host computer 1, a high-frequency RFID card writer 2, a main controller 3, an industrial switch 4, a distributed controller 5, a pedestrian barrier 6, a high-frequency card reader 7, an optical grating 8, a vehicle barrier 9, an ultra-high-frequency card reader 10, an LED screen 11, and an audible and visual alarm 12. The host computer 1 is connected to the high-frequency RIFD card writer 2 via a USB data cable. The host computer 1 is connected to the main controller 3 via Ethernet. The main controller 3 and the distributed controller 5 are connected to the industrial switch 4 via Ethernet. The pedestrian barrier 6, vehicle barrier 9, and audible and visual alarm 12 are connected to the digital output terminal of the distributed controller 5 via signal lines. The grating 8 and the audible and visual alarm 12 are connected to the digital input terminal of the distributed controller 5 via signal lines. The high-frequency card reader 7 and the ultra-high-frequency card reader 10 are connected to the distributed controller 5 via an RS485 bus. The LED screen is connected to the distributed controller 5 via Ethernet.

[0006] Furthermore, the high-frequency RFID card writer 2 and the high-frequency card reader 7 use a frequency of 13.56MHz.

[0007] Furthermore, the ultra-high frequency card reader 10 uses a frequency of 920MHz.

[0008] Furthermore, the main controller 3 uses a Siemens PLC1200.

[0009] Furthermore, the distributed controller 5 uses a Siemens ET200SP.

[0010] Furthermore, the pedestrian barrier 6 is a tripod turnstile, and the vehicle barrier 9 is a drop-down gate barrier.

[0011] The present invention provides one or more of the following technical effects: Firstly, the invention exhibits strong stability, security, and scalability, meeting the personnel management requirements of most hazardous locations. It can also be applied to explosion-proof locations when used with explosion-proof enclosures. Secondly, the system integrates pedestrian and vehicle personnel control functions. Pedestrian entrances and exits utilize tripod turnstiles combined with optical encoders, achieving high counting accuracy and anti-tailgating functionality. Combined with an LED outdoor display screen and audible and visual alarms, this not only improves management efficiency but also reduces human resource costs. Furthermore, as an integrated product, all components are mature products with proven market performance. Compared to customized R&D products, the system has lower costs, abundant spare parts, and simpler and more convenient operation and maintenance. Attached Figure Description

[0012] Figure 1 System control flowchart; Figure 2 System architecture diagram. Detailed Implementation

[0013] In response to safety management needs and the harsh conditions of industrial environments, this invention's staffing management system uses a PLC1200 as the main controller to control the entire staffing logic. It also uses an ET200SP as a remote distributed control station, RFID technology as an identification device, and a light grating as an inspection device. This effectively solves the problem of managing personnel and vehicles entering and exiting workshops in manufacturing enterprises, strictly controls the number of workers on the production site, records detailed information on personnel and vehicle entry and exit, improves the enterprise's safety management level and efficiency, and reduces the enterprise's human resource costs.

[0014] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments and accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments obtained. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0015] First, the overall working principle of the system is explained, and the system control flowchart is as follows: Figure 1 As shown. When the system is first started, it first needs to initialize personnel information, that is, register and issue cards to authorized employees or vehicles in the workshop, and at the same time send the registration data to the PLC. Then, the registered RFID cards can be used to enter and exit the workshop normally. When the RFID card readers located on both sides of the vehicle gate (main gate) collect the card swipe information, the PLC will determine whether the employee number has been registered. If the employee number has been registered, it will determine the entry and exit status of the card swipe; otherwise, it will prompt "invalid card" through the sound and light alarm. For the card swipe entry status, the PLC will register the employee number information, and then determine whether the current workshop is overcrowded by comparing the number of registered employees with the system's capacity. If it is overcrowded, the system will issue an "overcrowding" alarm. If it is not overcrowded, it will determine the door opening position according to the card permission. When the card permission is "vehicle", the system controls the vehicle gate to open; when the permission is "personnel", it controls the pedestrian gate (small door) to open. After the vehicle or pedestrian gate is opened, the system uses a light grating to determine the entry status and counts the number of people or vehicles entering. Simultaneously, it triggers a delayed closing time and updates the personnel information on the host computer and the occupancy data on the LED display. During the closing process, if an obstruction blocks the light grating signal, the system will issue an audible and visual alarm.

[0016] System architecture diagram as follows Figure 2As shown, the system consists of a host computer 1, a high-frequency RFID card writer 2, a main controller 3, an industrial switch 4, a distributed controller 5, a pedestrian barrier 6, a high-frequency card reader 7, an optical grating 8, a vehicle barrier 9, an ultra-high-frequency card reader 10, an LED screen 11, and an audible and visual alarm 12. The host computer 1 is connected to the high-frequency RFID card writer 2 via a USB data cable. The host computer 1 is connected to the main controller 3 via Ethernet. The main controller 3 and the distributed controller 5 are connected to the industrial switch 4 via Ethernet. The pedestrian barrier 6, the vehicle barrier 9, and the audible and visual alarm 12 are connected to the digital output terminals of the distributed controller 5 via signal lines. The optical grating 8 and the audible and visual alarm 12 are connected to the digital input terminals of the distributed controller 5 via signal lines. The high-frequency card reader 7 and the ultra-high-frequency card reader 10 are connected to the distributed controller 5 via an RS485 bus. The LED screen is connected to the distributed controller 5 via Ethernet.

[0017] The high-frequency RFID card writer 2 and the high-frequency card reader 7 use a frequency of 13.56MHz, the ultra-high frequency card reader 7 uses a frequency of 920MHz, the main controller 3 uses a Siemens PLC1200, the distributed controller 5 uses a Siemens ET200SP, the pedestrian barrier 6 uses a tripod turnstile, and the vehicle barrier 9 uses a lift-up fence barrier.

[0018] Specifically, the host computer 1 and the high-frequency card writer 2 are deployed in the production site monitoring room to issue cards corresponding to the authorized employee information of the RFID tags. The host computer 1 is also responsible for real-time monitoring and data storage of employees entering the production workshop. The main controller 3 and the industrial switch 4 are deployed in the field control cabinet to realize the logical control of the entire system, including personnel control, access control, RFID tag identification, LED screen data transmission, and audible and visual alarm control. Depending on the industry, they can also be deployed in explosion-proof electrical cabinets that meet the requirements. The distributed controller 5 is deployed in the chassis of the pedestrian barrier 6 or the workshop barrier 9, enabling the main controller 3 to remotely output control signals to the barrier and other equipment, as well as communication and grating signal acquisition functions. It can be expanded according to the number of entrances and exits on site. The pedestrian barrier 6 is installed at the pedestrian entrance and exit of the production site, and the high-frequency RFID card reader 7 is installed on both the inner and outer sides of the pedestrian barrier 6 to collect data from personnel entering and leaving the workshop. Vehicle gate 9 is deployed at the vehicle entrance and exit. UHF card readers 10 are installed inside and outside the vehicle gate, respectively identifying the RFID tags on vehicles entering and leaving the workshop. During system operation, the main controller 3 communicates in real-time with the HF card reader 7 and UHF card reader 10 via the distributed controller 5 to collect RFID card data detected by the readers. When RFID card data is collected, the main controller 3 determines whether the number of people and vehicles in the workshop exceeds the limit. If not, it controls the corresponding gate to open; otherwise, it controls the audible and visual alarm to issue an overcrowding voice prompt. Optical gratings 8 are installed inside the pedestrian and vehicle gates. When a pedestrian or vehicle passes by, the grating is blocked, triggering a count. If the gate is open and the grating is blocked for an extended period, the main controller 3 considers it blocked and closes the gate, controlling the audible and visual alarm 12 to issue a voice prompt. An LED screen and audible and visual alarm are installed near the entrance and exit gates to display the workshop's capacity and provide card-swiping voice prompts in real time.

[0019] This staffing management system uses a PLC1200 as the main controller to control the entire staffing logic, and an ET200SP as a remote distributed control station. The control unit boasts strong stability and scalability, making it applicable to various industrial sites and allowing for flexible expansion configurations based on the actual number of entrances and exits. Access control employs RFID technology, with all card readers being industrial-grade, stable, and reliable. High-frequency short-range card readers are used at pedestrian entrances and exits, while industrial-grade ultra-high-frequency long-range card readers are used at vehicle entrances and exits. Drivers can enter the workshop directly without disembarking and swiping their cards, significantly improving entrance and exit management efficiency. The pedestrian barrier uses a tripod turnstile combined with optical encoders, offering high counting accuracy and strong security, effectively preventing tailgating.

[0020] Obviously, those skilled in the art can make various modifications and variations to the embodiments of the present invention without departing from the spirit and scope of the embodiments of the present invention. Thus, if these modifications and variations to the embodiments of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention also intends to include these modifications and variations.

[0021] After six months of laboratory testing and two years of field application verification, the results show that the system is safe and stable, easy to use, accurate in staffing, and convenient in maintenance and replacement. It has now been applied in a military enterprise.

Claims

1. A PLC+RFID-based staff management system, characterized in that: The management system comprises a host computer (1), a high-frequency RFID card writer (2), a main controller (3), an industrial switch (4), a distributed controller (5), a pedestrian barrier (6), a high-frequency card reader (7), a grating (8), a vehicle barrier (9), an ultra-high frequency card reader (10), an LED screen (11) and an audible and visual alarm (12), The host computer (1) is connected with the high-frequency RFID card writer (2) through a USB data line, the host computer (1) is connected with the main controller (3) through an Ethernet, the main controller (3) and the distributed controller (5) are connected with the industrial switch (4) through the Ethernet, the pedestrian barrier (6), the vehicle barrier (9) and the audible and visual alarm (12) are respectively connected with the digital output end of the distributed controller (5) through signal lines, the grating (8) and the audible and visual alarm (12) are connected with the digital input end of the distributed controller (5) through signal lines, the high-frequency card reader (7) and the ultra-high frequency card reader (10) are connected with the distributed controller (5) through an RS485 bus, and the LED screen is connected with the distributed controller (5) through the Ethernet.

2. The PLC+RFID-based crowd management system according to claim 1, characterized in that: The high-frequency RFID card writer (2) and the high-frequency card reader (7) adopt a frequency of 13.56 MHz. 3.The PLC+RFID-based crowd management system according to claim 1, characterized in that: The ultra-high frequency card reader (10) uses a frequency of 920 MHz.

4. The PLC+RFID-based crowd management system according to claim 1, characterized in that: The main controller (3) uses a Siemens PLC1200.

5. The PLC+RFID-based crowd management system according to claim 1, characterized in that: The distributed controller (5) uses a Siemens ET200SP.

6. The PLC+RFID-based crowd management system according to claim 1, characterized in that: The pedestrian barrier (6) adopts a three-roller barrier, and the vehicle barrier (9) adopts a lifting fence barrier.

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