Liquid level monitoring and grading alarm system based on cooperation of double gateways

Abstract

The invention relates to the technical field of liquid level monitoring and alarming, and discloses a liquid level monitoring and grading alarming system based on double-gateway cooperation, and the system comprises a sensing assembly which is used for obtaining real-time liquid level sensing data; the heterogeneous gateway comprises a first gateway and a second gateway, the first gateway adopts RS485-MQTT dual protocol conversion to transmit the liquid level sensing data to the cloud, and the second gateway adopts MQTT-Modbus dual protocol conversion to transmit the liquid level sensing data to the local; the data distribution module is used for synchronously pushing the liquid level sensing data of the cloud to the mobile terminal; and the grading alarm module is used for carrying out grading alarm according to the liquid level sensing data of the local terminal, the cloud terminal and the mobile terminal. According to the invention, while the compatibility problem is solved, the liquid level sensing data can be transmitted to the local end, the cloud end and the mobile end, a cloud-end-ground three-level cooperative monitoring network is formed, an alarm can be given in time when abnormity occurs, and safe and stable operation of equipment is ensured.

Description

Technical Field

[0001] This application relates to the technical field of liquid level monitoring and alarm, and in particular to a liquid level monitoring and hierarchical alarm system based on dual gateway collaboration. Background Technology

[0002] In the industrial sector, liquid level monitoring systems are specialized systems used to observe changes in liquid level. They acquire data through sensors or visualization methods to ensure the safe operation of equipment.

[0003] In existing liquid level monitoring systems, liquid level sensors are used to monitor the liquid level in real time. At the same time, the liquid level sensor data is judged through an Internet of Things (IoT) platform, and warnings are issued based on the judgment results. However, during the transmission of liquid level sensor data, compatibility issues may arise between the field equipment and the IoT platform, resulting in data inconsistency problems. Therefore, how to process liquid level sensor data to ensure platform compatibility and normal data consistency is the fundamental problem that this invention aims to solve. Summary of the Invention

[0004] To ensure platform compatibility and data consistency, this application provides a liquid level monitoring and graded alarm system based on dual gateway collaboration, employing the following technical solution: A liquid level monitoring and graded alarm system based on dual gateway collaboration includes: Sensing components are used to acquire real-time liquid level sensing data; The heterogeneous gateway includes a first gateway and a second gateway. The first gateway uses RS485-MQTT dual protocol conversion to transmit the liquid level sensing data to the cloud, and the second gateway uses MQTT-Modbus dual protocol conversion to transmit the liquid level sensing data to the local machine. The data distribution module is used to synchronously push the liquid level sensing data from the cloud to the mobile terminal. The graded alarm module is used to generate graded alarms based on liquid level sensing data from local, cloud, and mobile terminals.

[0005] The above technical solution solves the compatibility problem and enables the liquid level sensing data to be transmitted to local, cloud and mobile devices, forming a three-level collaborative monitoring network of "cloud-device-ground". At the same time, through the hierarchical alarm module, it can promptly issue alarms when abnormal liquid levels occur, ensuring the safe and stable operation of industrial equipment.

[0006] Optionally, the process of performing graded alarms includes: When the liquid level sensor data is higher than the high water level threshold, the audible and visual alarm is triggered. When the liquid level sensor data is lower than the low water level threshold, an audible and visual alarm is triggered.

[0007] The above technical solution can ensure that the liquid level is between the low water level threshold and the high water level threshold, and can provide timely warnings when the liquid level is below the low water level threshold or above the high water level threshold.

[0008] Optionally, the process of performing graded alarms also includes: The first gateway actively uploads the liquid level sensing data to the cloud every Δt1 seconds, and the cloud forces the update of the liquid level sensing data on the mobile terminal every Δt2 seconds, where Δt2 > Δt1. When the liquid level sensor data is between the low water level threshold and the high water level threshold, a risk analysis is performed on the liquid level sensor data, and an early warning is issued based on the risk analysis results, and the values ​​of Δt1 and Δt2 are dynamically adjusted.

[0009] Through the above technical solution, the above early warning strategy, and the process of dynamically adjusting the time interval for uploading liquid level sensor data to the cloud and the time interval for forced updates to the mobile terminal, timely early warnings can be made based on the risk level of changes in liquid level sensor data. At the same time, the timeliness of the early warning process is improved adaptively, and the overall proportion of communication resource consumption is relatively low.

[0010] Optionally, the process of performing risk analysis on liquid level sensing data includes: Obtain the change in liquid level ΔH every Δt1 seconds, calculate the rate of change of liquid level v1 by ΔH / Δt1, compare v with the reference rate v0, and obtain the rate reference difference Δv. When v1≤v0, Δv=0; otherwise, Δv=v1-v0. Get the Δv of n consecutive time points before the current time point, where n≥2; calculate the standard deviation Δs of the n+1 Δv; Δv and Δs are normalized, and the risk value is determined based on Δv and Δs. Risk is then assessed based on the risk value. The risk value is positively correlated with Δv and negatively correlated with Δs.

[0011] The above technical solution provides a specific method for risk analysis using liquid level sensor data. By analyzing the liquid level change rate v1 and standard deviation Δs, the degree of liquid level anomaly can be judged based on the magnitude of the risk value. An alarm is triggered when the degree of liquid level anomaly is high, reducing safety hazards in industrial production. Furthermore, by adjusting the data update frequency, the monitoring accuracy can be adaptively improved when the liquid level risk is high.

[0012] Optionally, the process of dynamically adjusting the values ​​of Δt1 and Δt2 includes: Compare the risk value with the preset risk value: When the risk value is less than or equal to the preset risk value, keep the values ​​of Δt1 and Δt2 unchanged. When the risk value is greater than the preset risk value, the reduction of Δt1 and Δt2 is determined based on the interval in which the difference between the risk value and the preset risk value lies, and the larger the difference, the greater the reduction.

[0013] The above technical solution compares the risk value with a preset risk value. When the risk value is less than or equal to the preset risk value, the values ​​of Δt1 and Δt2 remain unchanged. When the risk value is greater than the preset risk value, the update frequency is adaptively adjusted according to the range of the difference between the risk value and the preset risk value. By adjusting the data update frequency, the accuracy of monitoring is adaptively improved when the liquid level risk is high.

[0014] Optionally, RS485 data is verified using CRC and transmitted via MQTT QoS1.

[0015] Optionally, a maintenance alarm is triggered when the CRC check fails three times consecutively.

[0016] The above technical solutions enable timely processing of abnormal data.

[0017] Optionally, the graded alarm module includes an audible and visual alarm, an LED display screen, and an IO8442 module; The DI channel of the IO8442 module is connected to the audible and visual alarm, and the DO channel of the IO8442 module drives the LED display screen to achieve data synchronization.

[0018] The above technical solution enables the hardware implementation of an audible and visual alarm.

[0019] In summary, this application includes at least one of the following beneficial technical effects: First, this invention solves the compatibility problem and can transmit liquid level sensing data to local, cloud and mobile terminals to form a three-level collaborative monitoring network of "cloud-terminal-ground". At the same time, through the hierarchical alarm module, it can promptly issue alarms when abnormal liquid levels occur, ensuring the safe and stable operation of industrial equipment.

[0020] Second, this invention uses the rate of change and standard deviation of liquid level to judge the degree of liquid level anomaly by the magnitude of the risk value, and issues an alarm when the degree of liquid level anomaly is high, reducing safety hazards in industrial production; at the same time, it dynamically adjusts the time interval for uploading liquid level sensor data to the cloud and the time interval for forced updates to the mobile terminal, which can make timely warnings based on the risk level of changes in liquid level sensor data, adaptively improve the accuracy of monitoring when the liquid level risk is high, and adaptively improve the timeliness of the warning process, while having a low overall proportion of communication resource consumption. Attached Figure Description

[0021] Figure 1This is a logical diagram of a liquid level monitoring and graded alarm system based on dual-gateway collaboration. Detailed Implementation

[0022] The embodiments of this application are described in detail below, and examples of the embodiments are shown in the accompanying drawings.

[0023] In the description of this specification, the references to "certain embodiments," "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples" refer to specific features, structures, materials, or characteristics described in connection with the described embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0024] This application discloses a liquid level monitoring and graded alarm system based on dual gateway collaboration, referring to... Figure 1 The system includes sensing components, a heterogeneous gateway, a data distribution module, and a tiered alarm module. The sensing components are internal to the device and can employ ultrasonic level sensors, radar level sensors, float-type level sensors, pressure level sensors, or capacitive level sensors to acquire real-time level data. The heterogeneous gateway includes a first gateway and a second gateway. The first gateway uses RS485-MQTT dual-protocol conversion to transmit the level sensing data to the cloud, while the second gateway uses MQTT-Modbus dual-protocol conversion to transmit the level sensing data locally. The dual-protocol conversion is implemented through a multi-protocol conversion engine, which is configured within the gateway firmware. The current lightweight algorithm for protocol conversion, such as the register mapping rules from MQTT to Modbus, solves the compatibility problem between industrial field equipment and IoT platforms. Simultaneously, the data splitting module synchronously pushes liquid level sensing data from the cloud to mobile terminals. The tiered alarm module performs tiered alarms based on liquid level sensing data from local, cloud, and mobile terminals. Through this system, compatibility issues are resolved, and liquid level sensing data can be transmitted to local, cloud, and mobile terminals, forming a three-tiered collaborative monitoring network of "cloud-edge-ground." Furthermore, the tiered alarm module ensures timely alarms when abnormal liquid levels occur, guaranteeing the safe and stable operation of industrial field equipment.

[0025] The graded alarm module includes an audible and visual alarm, an LED display screen, and an IO8442 module. The DI channel of the IO8442 module is connected to the audible and visual alarm, and the DO channel of the IO8442 module drives the LED display screen to achieve data synchronization. The graded alarm process includes: triggering the audible and visual alarm when the liquid level sensor data is higher than the high water level threshold; triggering the audible and visual alarm when the liquid level sensor data is lower than the low water level threshold. In this embodiment, the high water level threshold is 90% of the water tank height, and the low water level threshold is 15% of the water tank height. The process of triggering the audible and visual alarm is as follows: triggering a normally open relay when the liquid level reaches the high water level threshold, and triggering a normally closed relay when the liquid level reaches the low water level threshold. Through this setting process, it can be ensured that the liquid level is between the low water level threshold and the high water level threshold.

[0026] In one embodiment, the process of classifying alarms to assess the risks associated with liquid level data further includes: the first gateway actively uploads liquid level sensing data to the cloud every Δt1 seconds; the cloud forcibly updates the liquid level sensing data on the mobile device every Δt2 seconds. In this embodiment, Δt1 is 30 seconds and Δt2 is 180 seconds. When the liquid level sensing data falls between the low and high water level thresholds, a risk analysis is performed on the liquid level sensing data. This process first obtains the change in liquid level ΔH every Δt1 seconds, calculates the liquid level change rate v1 using ΔH / Δt1, and compares v1 with a reference rate v0. The reference rate v0 is set based on the risk threshold of historical liquid level change data. When v1 is higher than the reference rate v0, it indicates a higher risk. Therefore, when v1 ≤ v0, the rate reference difference Δv = 0, meaning this parameter is low. Risk is not considered; otherwise, let the rate reference difference Δv = v1 - v0. Then, obtain Δv for n consecutive time points before the current time point, n ≥ 2; calculate the standard deviation Δs of n+1 Δv. Therefore, Δv reflects the abnormal state of the liquid level change rate. At the same time, since the actual change of liquid level will show irregular characteristics according to different usage requirements, if the standard deviation Δs approaches 0, it indicates that the change trend of Δv is relatively consistent, that is, there is a high risk of leakage. Therefore, the liquid level risk is judged by Δs. Δv and Δs are normalized, and the risk value is determined based on Δv and Δs. The magnitude of the risk value is positively correlated with Δv and negatively correlated with Δs. Therefore, the larger the risk value, the greater the risk of liquid level. Early warning is given based on the risk analysis results, and the values ​​of Δt1 and Δt2 are dynamically adjusted. The process of dynamically adjusting the values ​​of Δt1 and Δt2 includes: comparing the risk value with a preset risk value; the preset risk value is set based on empirical data, and when the risk value is less than or equal to the preset risk value, the values ​​of Δt1 and Δt2 remain unchanged; when the risk value is greater than the preset risk value, the reduction in the values ​​of Δt1 and Δt2 is determined based on the range of the difference between the risk value and the preset risk value. The larger the difference, the greater the reduction. The specific correspondence is set according to actual selection. For example, reductions of 5s, 10s, 15s, and 20s are set according to the range of the difference between the risk value and the preset risk value. By dynamically adjusting the time interval for uploading liquid level sensor data to the cloud and the time interval for forced updates to the mobile terminal, the accuracy of monitoring can be improved adaptively when the liquid level risk is high. Furthermore, the process of issuing an early warning based on the risk analysis results involves comparing the risk value with a risk threshold. The risk threshold is determined based on test data, and its value is higher than the preset risk value. Therefore, when the risk value exceeds the risk threshold, it indicates a high degree of liquid level abnormality, thus triggering an alarm and reducing safety hazards in industrial production.

[0027] In one embodiment, the RS485 data in the RS485-MQTT dual-protocol conversion uses CRC checksum and is transmitted via MQTT QoS1, where QoS represents the MQTT Quality of Service, and QoS1 indicates a QoS level of 1. After sending a message, the sender checks whether the receiver has successfully received it. After sending the message, the sender waits for the receiver's confirmation. Upon successful reception, the receiver sends a PUBACK acknowledgment message to the sender. If the sender receives this PUBACK message, it knows the message has been successfully received. If no PUBACK message is received after a period of time, the sender resends the message and waits for the receiver's PUBACK message again. Therefore, when QoS=1, the sender will repeatedly send the same message until it receives a PUBACK message from the receiver, ensuring that each message is transmitted at least once when QoS=1. When a CRC check fails three times consecutively, a maintenance alarm is triggered. CRC (Cyclic Redundancy Check) is a commonly used error detection method, mainly used for error detection during data transmission or storage. It generates a fixed-length checksum, appends it to the data, and the receiver verifies the integrity of the data using the same algorithm. This process enables timely handling of abnormal data.

[0028] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A liquid level monitoring and graded alarm system based on dual gateway collaboration, characterized in that, include: Sensing components are used to acquire real-time liquid level sensing data; The heterogeneous gateway includes a first gateway and a second gateway. The first gateway uses RS485-MQTT dual protocol conversion to transmit the liquid level sensing data to the cloud, and the second gateway uses MQTT-Modbus dual protocol conversion to transmit the liquid level sensing data to the local machine. The data distribution module is used to synchronously push the liquid level sensing data from the cloud to the mobile terminal. The graded alarm module is used to generate graded alarms based on liquid level sensing data from local, cloud, and mobile terminals.

2. The liquid level monitoring and graded alarm system based on dual gateway collaboration according to claim 1, characterized in that, The process of implementing graded alarms includes: When the liquid level sensor data is higher than the high water level threshold, the audible and visual alarm is triggered. When the liquid level sensor data is lower than the low water level threshold, an audible and visual alarm is triggered.

3. The liquid level monitoring and graded alarm system based on dual gateway collaboration according to claim 2, characterized in that, The process of implementing graded alarms also includes: The first gateway actively uploads the liquid level sensing data to the cloud every Δt1 seconds, and the cloud forces the update of the liquid level sensing data on the mobile terminal every Δt2 seconds, where Δt2 > Δt1. When the liquid level sensor data is between the low water level threshold and the high water level threshold, a risk analysis is performed on the liquid level sensor data, and an early warning is issued based on the risk analysis results, and the values ​​of Δt1 and Δt2 are dynamically adjusted.

4. The liquid level monitoring and graded alarm system based on dual gateway collaboration according to claim 3, characterized in that, The process of conducting risk analysis on liquid level sensor data includes: Obtain the change in liquid level ΔH every Δt1 seconds, calculate the rate of change of liquid level v1 by ΔH / Δt1, compare v with the reference rate v0, and obtain the rate reference difference Δv. When v1≤v0, Δv=0; otherwise, Δv=v1-v0. Get the Δv of n consecutive time points before the current time point, where n≥2; calculate the standard deviation Δs of the n+1 Δv; Δv and Δs are normalized, and the risk value is determined based on Δv and Δs. Risk is then assessed based on the risk value. The risk value is positively correlated with Δv and negatively correlated with Δs.

5. The liquid level monitoring and graded alarm system based on dual gateway collaboration according to claim 4, characterized in that, The process of dynamically adjusting the values ​​of Δt1 and Δt2 includes: Compare the risk value with the preset risk value: When the risk value is less than or equal to the preset risk value, keep the values ​​of Δt1 and Δt2 unchanged. When the risk value is greater than the preset risk value, the reduction of Δt1 and Δt2 is determined based on the interval in which the difference between the risk value and the preset risk value lies, and the larger the difference, the greater the reduction.

6. The liquid level monitoring and graded alarm system based on dual gateway collaboration according to claim 1, characterized in that, RS485 data uses CRC checksum and is transmitted via MQTT QoS1.

7. The liquid level monitoring and graded alarm system based on dual gateway collaboration according to claim 6, characterized in that, A maintenance alarm is triggered when the CRC check fails three times in a row.

8. The liquid level monitoring and graded alarm system based on dual gateway collaboration according to claim 1, characterized in that, The graded alarm module includes an audible and visual alarm, an LED display screen, and an IO8442 module; The DI channel of the IO8442 module is connected to the audible and visual alarm, and the DO channel of the IO8442 module drives the LED display screen to achieve data synchronization.

Images