Remote monitoring system and method for calcium carbide method PVC production equipment

Abstract

The invention relates to the technical field of remote monitoring, in particular to a calcium carbide method PVC production equipment remote monitoring system and method, and the system comprises a data collection layer, a data aggregation node, a network transmission layer and a cloud processing layer. The data aggregation node performs data cleaning and format conversion on the signals acquired by the sensors to obtain standardized data to be transmitted; the network transmission layer is connected with the data aggregation node and is used for receiving standardized data to be transmitted; the cloud processing layer is connected with the network transmission layer and receives encrypted data; the equipment operation state correlation analysis model takes operation parameters of the calcium carbide crusher as a core analysis object, and accurately judges the fault type of the calcium carbide crusher according to a preset fault judgment rule by analyzing the change trend of the two types of parameters and carrying out correlation operation. The equipment operation state correlation analysis model of the data analysis module can accurately determine the fault type of the calcium carbide crusher by performing correlation operation on multi-source data.

Description

Technical Field

[0001] This invention relates to the field of remote monitoring technology, specifically to a remote monitoring system and method for calcium carbide PVC production equipment. Background Technology

[0002] Polyvinyl chloride (PVC), as an important organic synthetic material, is widely used in industrial production and daily life. Among them, the calcium carbide process is the mainstream process for PVC production in my country. This process involves key equipment such as calcium carbide crushers and acetylene generators. The production environment is characterized by high dust levels and the presence of flammable and explosive gases such as acetylene. Real-time and accurate monitoring of equipment operation status is directly related to production safety and efficiency. Therefore, building a reliable monitoring system is crucial.

[0003] Traditional monitoring methods for calcium carbide-based PVC production equipment mainly rely on manual inspections or localized DCS / SCADA systems. However, these methods have many insurmountable drawbacks: manual inspections are limited by the inspection cycle, have obvious monitoring blind spots, cannot achieve continuous monitoring of equipment operating status, and are difficult to respond quickly when equipment suddenly fails, which can easily lead to production interruptions or even safety accidents; localized monitoring systems suffer from data silos, with monitoring data from various devices stored locally, making it impossible to achieve cross-device and cross-workshop data integration and analysis, and lacking remote access and control capabilities, making it difficult to meet the needs of modern production management for remote control.

[0004] With the rise of Industrial Internet of Things (IIoT) technology, remote monitoring technology has been gradually applied in the chemical production field, providing new solutions to the pain points of traditional monitoring. For example, Chinese patent CN105171748A discloses a remote status monitoring method for robots and production line equipment. This method adopts a technical architecture of data acquisition, wireless transmission, and mobile terminal interaction. By collecting equipment operation data and transmitting it to the backend for processing via the network, the monitoring information is then displayed to the user through a mobile terminal, thus realizing remote monitoring of the equipment to a certain extent.

[0005] However, applying the aforementioned existing technologies to calcium carbide-based PVC production scenarios still presents significant limitations, failing to meet the actual production requirements for the stability, efficiency, and accuracy of the monitoring system. Firstly, regarding data transmission stability, the existing wireless transmission method lacks redundancy design for the complex environment of chemical industrial parks. These parks often suffer from unstable network signals due to their remote locations or the signal shielding effect of large metal equipment. If the main transmission link is interrupted, the operating data of critical equipment such as the calcium carbide crusher and acetylene generator cannot be transmitted in a timely manner, potentially resulting in data loss. Furthermore, the technology lacks a backup transmission link based on signal strength monitoring, failing to guarantee the continuity of data transmission. Secondly, in terms of data processing… Regarding storage, the high-frequency data generated by sensors during the calcium carbide PVC production process is enormous. This existing technology does not mention a data preprocessing mechanism at the edge, directly transmitting the raw data to the backend, which can easily lead to excessive backend processing load. Furthermore, it lacks a dedicated storage architecture designed for the highly time-sensitive sensor data, making it difficult to balance data read / write performance with storage costs. Finally, in terms of fault diagnosis accuracy, this existing technology does not explicitly employ a multi-parameter correlation analysis method for fault determination. If directly applied to monitoring calcium carbide PVC production equipment, the use of a single-parameter threshold alarm mode makes it impossible to perform correlation analysis on multi-source data such as vibration and temperature from the calcium carbide crusher, leading to false alarms or missed alarms, and making it difficult to accurately determine the type of equipment fault. Summary of the Invention

[0006] To address the problems existing in the prior art, the present invention provides a remote monitoring system and method for calcium carbide PVC production equipment.

[0007] To achieve the above objectives, the technical solution of the present invention is as follows:

[0008] A remote monitoring system for calcium carbide-based PVC production equipment includes a data acquisition layer, a data aggregation node, a network transmission layer, and a cloud processing layer;

[0009] The data acquisition layer includes vibration sensors and temperature sensors installed on the calcium carbide crusher, and pressure sensors and gas concentration sensors installed on the acetylene generator;

[0010] The data aggregation node is connected to each sensor in the data acquisition layer. The data aggregation node performs data cleaning and format conversion on the signals collected by each sensor. Data cleaning is used to remove abnormal interference data, and format conversion is used to convert heterogeneous data from different types of sensors into a unified standard format to obtain standardized data to be transmitted.

[0011] The network transmission layer is connected to the data aggregation node and receives standardized data to be transmitted. The network transmission layer has a multi-link redundant transmission channel, including an industrial cellular network channel as the primary transmission link and a satellite communication channel as a backup transmission link. The data aggregation node can monitor the signal strength of the primary transmission link in real time. When the signal strength of the primary transmission link is detected to be lower than a preset first threshold, it automatically switches the data transmission path to the backup transmission link. When the signal strength of the primary transmission link recovers to above the first threshold, it can automatically switch back to the primary link to ensure uninterrupted data transmission. The network transmission layer also includes a VPN encryption module to encrypt the data during transmission.

[0012] The cloud processing layer is connected to the network transmission layer and receives encrypted data. The cloud processing layer includes a distributed database module and a data analysis module. The distributed database module decrypts and stores the received encrypted data. The data analysis module has a device operation status correlation analysis model. This model takes the operating parameters of the calcium carbide crusher as the core analysis object. By calling historical and real-time vibration amplitude data collected by vibration sensors and historical and real-time temperature data collected by temperature sensors stored in the distributed database, it analyzes the changing trends of these two types of parameters and performs correlation calculations. Based on preset fault judgment rules, it accurately determines the fault type of the calcium carbide crusher. The cloud processing layer also includes a user interaction module, which is connected to the data analysis module and the distributed database module. This module is used to display device operating parameters, fault judgment results, and alarm information pushes to the user.

[0013] Furthermore, the user interaction module includes both web and mobile access methods, and alarm information is pushed through at least two of the following methods: pop-up notifications, SMS notifications, and APP push notifications.

[0014] Furthermore, the industrial cellular network channel adopts an industrial-grade 4G or 5G network, and the data aggregation node has a built-in signal strength monitoring chip.

[0015] Furthermore, the distributed database module adopts a storage architecture that combines time-series database and relational database. The time-series database is used to store the time-series operation data collected in real time by the sensor, while the relational database is used to store basic equipment information, fault records, and user information data. It also adopts a multi-dimensional indexing strategy based on production workshop, equipment type, and collection time.

[0016] Furthermore, the equipment operation status correlation analysis model is trained and optimized using historical operation data and fault case data as training sets through a random forest algorithm; the fault judgment rules include: when the vibration amplitude exceeds the preset normal range and the temperature shows a continuous upward trend, it is judged as a wear fault of equipment components; when the vibration amplitude suddenly surges and the temperature does not change significantly, it is judged as a foreign object jamming fault.

[0017] This invention also includes the following technical solutions:

[0018] A remote monitoring method for calcium carbide-based PVC production equipment based on the above system includes the following steps:

[0019] S1. Install vibration and temperature sensors of the data acquisition layer on the body and motor of the calcium carbide crusher, and pressure and gas concentration sensors on the reaction chamber and exhaust port of the acetylene generator; configure the communication parameters between the data aggregation node and each sensor, set data cleaning rules and unified standards for format conversion, initialize the VPN encryption parameters of the network transmission layer and the first threshold for switching between primary and backup links, and complete the storage architecture configuration of the distributed database of the cloud processing layer and the deployment of the equipment operation status correlation analysis model.

[0020] S2. The sensors in the data acquisition layer collect the operating parameters of the equipment in real time and transmit the collected raw signals to the data aggregation node. The data aggregation node performs data cleaning according to preset rules to remove abnormal interference data, and then converts the heterogeneous data into a unified standard format through format conversion to obtain standardized data to be transmitted.

[0021] S3. The data aggregation node transmits standardized data to the network transmission layer, while simultaneously monitoring the signal strength of the main transmission link in real time through a built-in signal strength monitoring chip. If the signal strength is higher than a preset first threshold, the data is transmitted encrypted through the main transmission link. If the signal strength is lower than the first threshold, the data is automatically switched to the backup transmission link for encrypted transmission, and automatically switched back after the main link signal is restored.

[0022] S4. The cloud processing layer receives encrypted data transmitted from the network transmission layer. After being decrypted by the distributed database module, the data is classified and stored according to the strategy of storing time-series operational data in a time-series database and storing basic information in a relational database. Indexes are also established through multiple dimensions such as production workshop, equipment type, and collection time. The data analysis module calls historical and real-time data from the distributed database. Through the equipment operation status correlation analysis model, the vibration amplitude data and temperature data of the calcium carbide crusher are analyzed for trends and correlation calculations. The fault type is determined by combining the preset fault judgment rules. At the same time, the monitoring data of the pressure sensor and gas concentration sensor are processed simultaneously.

[0023] The S5 cloud processing layer's user interaction module displays the device's real-time operating parameters and the fault determination results from the data analysis module in a visual format; if a fault is determined or the monitored parameters exceed the normal range, an alarm message is pushed.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] This invention provides a remote monitoring system and method for calcium carbide-based PVC production equipment. The data acquisition layer precisely deploys dedicated sensors for key equipment such as the calcium carbide crusher and acetylene generator. Combined with data aggregation nodes for cleaning and format conversion preprocessing, this not only ensures the validity and standardization of the collected data but also reduces the burden of subsequent transmission and processing, solving the problems of poor data accuracy and data silos in traditional manual inspection systems. The network transmission layer adopts a multi-link redundant transmission channel with industrial cellular networks as the primary and satellite communication as a backup. Combined with real-time monitoring and automatic switching of the main link signal strength by the data aggregation nodes, and a VPN encryption module, this ensures the continuity and stability of data transmission in the complex environment of the chemical industrial park, avoiding data loss due to a single link interruption, and ensuring the security of transmitted data. The cloud processing layer employs a hybrid storage architecture of distributed database modules and a multi-dimensional indexing strategy, achieving efficient storage and rapid retrieval of massive time-series data. The equipment operation status correlation analysis model of the data analysis module can accurately determine the fault type of the calcium carbide crusher by performing correlation calculations on multi-source data. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this invention clearer, the invention is further described in detail below through specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0027] A remote monitoring system for calcium carbide-based PVC production equipment includes a data acquisition layer, a data aggregation node, a network transmission layer, and a cloud processing layer;

[0028] The data acquisition layer includes vibration sensors and temperature sensors installed on the calcium carbide crusher, and pressure sensors and gas concentration sensors installed on the acetylene generator;

[0029] The data aggregation node is connected to each sensor in the data acquisition layer. The data aggregation node performs data cleaning and format conversion on the signals collected by each sensor. Data cleaning is used to remove abnormal interference data, and format conversion is used to convert heterogeneous data from different types of sensors into a unified standard format to obtain standardized data to be transmitted.

[0030] The network transmission layer is connected to the data aggregation node and receives standardized data to be transmitted. The network transmission layer has a multi-link redundant transmission channel, including an industrial cellular network channel as the primary transmission link and a satellite communication channel as a backup transmission link. The data aggregation node can monitor the signal strength of the primary transmission link in real time. When the signal strength of the primary transmission link is detected to be lower than a preset first threshold, it automatically switches the data transmission path to the backup transmission link. When the signal strength of the primary transmission link recovers to above the first threshold, it can automatically switch back to the primary link to ensure uninterrupted data transmission. The network transmission layer also includes a VPN encryption module to encrypt the data during transmission.

[0031] The cloud processing layer is connected to the network transmission layer and receives encrypted data. The cloud processing layer includes a distributed database module and a data analysis module. The distributed database module decrypts and stores the received encrypted data. The data analysis module has a device operation status correlation analysis model. This model takes the operating parameters of the calcium carbide crusher as the core analysis object. By calling historical and real-time vibration amplitude data collected by vibration sensors and historical and real-time temperature data collected by temperature sensors stored in the distributed database, it analyzes the changing trends of these two types of parameters and performs correlation calculations. Based on preset fault judgment rules, it accurately determines the fault type of the calcium carbide crusher. The cloud processing layer also includes a user interaction module, which is connected to the data analysis module and the distributed database module. This module is used to display device operating parameters, fault judgment results, and alarm information pushes to the user.

[0032] In one embodiment of the present invention, the user interaction module includes two access methods: web terminal and mobile terminal. Alarm information is pushed through at least two of the following methods: pop-up prompts, SMS notifications, and APP push notifications.

[0033] In one embodiment of the present invention, the industrial cellular network channel adopts an industrial-grade 4G or 5G network, and the data aggregation node has a built-in signal strength monitoring chip.

[0034] In one embodiment of the present invention, the distributed database module adopts a storage architecture that combines a time-series database and a relational database. The time-series database is used to store the time-series operation data collected in real time by the sensor, and the relational database is used to store basic equipment information, fault records, and user information data. Furthermore, a multi-dimensional indexing strategy based on production workshop, equipment type, and collection time is adopted.

[0035] In one embodiment of the present invention, the equipment operation status correlation analysis model is trained and optimized using historical operation data and fault case data as training sets through a random forest algorithm; the fault determination rules include: when the vibration amplitude exceeds the preset normal range and the temperature shows a continuous upward trend, it is determined to be a wear fault of equipment components; when the vibration amplitude suddenly surges and the temperature does not change significantly, it is determined to be a foreign object jamming fault.

[0036] A remote monitoring method for calcium carbide-based PVC production equipment based on the above system includes the following steps:

[0037] S1. Install vibration and temperature sensors of the data acquisition layer on the body and motor of the calcium carbide crusher, and pressure and gas concentration sensors on the reaction chamber and exhaust port of the acetylene generator; configure the communication parameters between the data aggregation node and each sensor, set data cleaning rules and unified standards for format conversion, initialize the VPN encryption parameters of the network transmission layer and the first threshold for switching between primary and backup links, and complete the storage architecture configuration of the distributed database of the cloud processing layer and the deployment of the equipment operation status correlation analysis model.

[0038] S2. The sensors in the data acquisition layer collect the operating parameters of the equipment in real time and transmit the collected raw signals to the data aggregation node. The data aggregation node performs data cleaning according to preset rules to remove abnormal interference data, and then converts the heterogeneous data into a unified standard format through format conversion to obtain standardized data to be transmitted.

[0039] S3. The data aggregation node transmits standardized data to the network transmission layer, while simultaneously monitoring the signal strength of the main transmission link in real time through a built-in signal strength monitoring chip. If the signal strength is higher than a preset first threshold, the data is transmitted encrypted through the main transmission link. If the signal strength is lower than the first threshold, the data is automatically switched to the backup transmission link for encrypted transmission, and automatically switched back after the main link signal is restored.

[0040] S4. The cloud processing layer receives encrypted data transmitted from the network transmission layer. After being decrypted by the distributed database module, the data is classified and stored according to the strategy of storing time-series operational data in a time-series database and storing basic information in a relational database. Indexes are also established through multiple dimensions such as production workshop, equipment type, and collection time. The data analysis module calls historical and real-time data from the distributed database. Through the equipment operation status correlation analysis model, the vibration amplitude data and temperature data of the calcium carbide crusher are analyzed for trends and correlation calculations. The fault type is determined by combining the preset fault judgment rules. At the same time, the monitoring data of the pressure sensor and gas concentration sensor are processed simultaneously.

[0041] The S5 cloud processing layer's user interaction module displays the device's real-time operating parameters and the fault determination results from the data analysis module in a visual format; if a fault is determined or the monitored parameters exceed the normal range, an alarm message is pushed.

[0042] This invention provides a remote monitoring system and method for calcium carbide-based PVC production equipment. The data acquisition layer precisely deploys dedicated sensors for key equipment such as the calcium carbide crusher and acetylene generator. Combined with data aggregation nodes for cleaning and format conversion preprocessing, this not only ensures the validity and standardization of the collected data but also reduces the burden of subsequent transmission and processing, solving the problems of poor data accuracy and data silos in traditional manual inspection systems. The network transmission layer adopts a multi-link redundant transmission channel with industrial cellular networks as the primary and satellite communication as a backup. Combined with real-time monitoring and automatic switching of the main link signal strength by the data aggregation nodes, and a VPN encryption module, this ensures the continuity and stability of data transmission in the complex environment of the chemical industrial park, avoiding data loss due to a single link interruption, and ensuring the security of transmitted data. The cloud processing layer employs a hybrid storage architecture of distributed database modules and a multi-dimensional indexing strategy, achieving efficient storage and rapid retrieval of massive time-series data. The equipment operation status correlation analysis model of the data analysis module can accurately determine the fault type of the calcium carbide crusher by performing correlation calculations on multi-source data.

[0043] The foregoing descriptions have outlined some exemplary embodiments of the present invention. It is understood that these embodiments are merely illustrative and do not constitute a limitation on the scope of protection of the present invention. Features in these embodiments can be rearranged in suitable ways, and the resulting solutions remain within the scope of protection claimed by the present invention. All other embodiments obtained by those skilled in the art based on the foregoing embodiments without inventive effort, i.e., all modifications, equivalent substitutions, and improvements made within the spirit and principles of this application, fall within the scope of protection claimed by the present invention.

Claims

1. A remote monitoring system for calcium carbide-based PVC production equipment, characterized in that, It includes a data acquisition layer, data aggregation nodes, network transmission layer, and cloud processing layer; The data acquisition layer includes vibration sensors and temperature sensors installed on the calcium carbide crusher, and pressure sensors and gas concentration sensors installed on the acetylene generator; The data aggregation node is connected to each sensor in the data acquisition layer. The data aggregation node performs data cleaning and format conversion on the signals collected by each sensor. Data cleaning is used to remove abnormal interference data, and format conversion is used to convert heterogeneous data from different types of sensors into a unified standard format to obtain standardized data to be transmitted. The network transmission layer is connected to the data aggregation node and receives standardized data to be transmitted. The network transmission layer has a multi-link redundant transmission channel, including an industrial cellular network channel as the primary transmission link and a satellite communication channel as a backup transmission link. The data aggregation node can monitor the signal strength of the primary transmission link in real time. When the signal strength of the primary transmission link is detected to be lower than a preset first threshold, it automatically switches the data transmission path to the backup transmission link. When the signal strength of the primary transmission link recovers to above the first threshold, it can automatically switch back to the primary link to ensure uninterrupted data transmission. The network transmission layer also includes a VPN encryption module to encrypt the data during transmission. The cloud processing layer is connected to the network transmission layer and receives encrypted data. The cloud processing layer includes a distributed database module and a data analysis module. The distributed database module decrypts and stores the received encrypted data. The data analysis module has a device operation status correlation analysis model. This model takes the operating parameters of the calcium carbide crusher as the core analysis object. By calling historical and real-time vibration amplitude data collected by vibration sensors and historical and real-time temperature data collected by temperature sensors stored in the distributed database, it analyzes the changing trends of these two types of parameters and performs correlation calculations. Based on preset fault judgment rules, it accurately determines the fault type of the calcium carbide crusher. The cloud processing layer also includes a user interaction module, which is connected to the data analysis module and the distributed database module. This module is used to display device operating parameters, fault judgment results, and alarm information pushes to the user.

2. The remote monitoring system for calcium carbide-based PVC production equipment according to claim 1, characterized in that, The user interaction module includes two access methods: web and mobile. Alarm information is pushed through at least two of the following methods: pop-up notifications, SMS notifications, and APP push notifications.

3. The remote monitoring system for calcium carbide-based PVC production equipment according to claim 1, characterized in that, The industrial cellular network channel adopts an industrial-grade 4G or 5G network, and the data aggregation node has a built-in signal strength monitoring chip.

4. The remote monitoring system for calcium carbide-based PVC production equipment according to claim 1, characterized in that, The distributed database module adopts a storage architecture that combines time-series database and relational database. The time-series database is used to store the time-series operation data collected in real time by the sensor, while the relational database is used to store basic equipment information, fault records, and user information data. It also adopts a multi-dimensional indexing strategy based on production workshop, equipment type, and collection time.

5. The remote monitoring system for calcium carbide-based PVC production equipment according to claim 1, characterized in that, The equipment operation status correlation analysis model is obtained by training and optimizing the random forest algorithm using historical operation data and fault case data as training sets. The fault determination rules include: when the vibration amplitude exceeds the preset normal range and the temperature shows a continuous upward trend, it is determined to be a wear fault of equipment components; when the vibration amplitude suddenly surges and the temperature does not change significantly, it is determined to be a foreign object jamming fault.

6. A remote monitoring method for calcium carbide PVC production equipment based on the system described in any one of claims 1 to 5, characterized in that, Includes the following steps: S1. Install vibration and temperature sensors of the data acquisition layer on the body and motor of the calcium carbide crusher, and pressure and gas concentration sensors on the reaction chamber and exhaust port of the acetylene generator; configure the communication parameters between the data aggregation node and each sensor, set data cleaning rules and unified standards for format conversion, initialize the VPN encryption parameters of the network transmission layer and the first threshold for switching between primary and backup links, and complete the storage architecture configuration of the distributed database of the cloud processing layer and the deployment of the equipment operation status correlation analysis model. S2. The sensors in the data acquisition layer collect the operating parameters of the equipment in real time and transmit the collected raw signals to the data aggregation node. The data aggregation node performs data cleaning according to preset rules to remove abnormal interference data, and then converts the heterogeneous data into a unified standard format through format conversion to obtain standardized data to be transmitted. S3. The data aggregation node transmits standardized data to the network transmission layer, while simultaneously monitoring the signal strength of the main transmission link in real time through a built-in signal strength monitoring chip. If the signal strength is higher than a preset first threshold, the data is transmitted encrypted through the main transmission link. If the signal strength is lower than the first threshold, it will automatically switch to the backup transmission link to encrypt and transmit data, and will automatically switch back after the main link signal is restored. S4. The cloud processing layer receives encrypted data transmitted from the network transmission layer. After being decrypted by the distributed database module, the data is classified and stored according to the strategy of storing time-series operational data in a time-series database and storing basic information in a relational database. Indexes are also established through multiple dimensions such as production workshop, equipment type, and collection time. The data analysis module calls historical and real-time data from the distributed database. Through the equipment operation status correlation analysis model, the vibration amplitude data and temperature data of the calcium carbide crusher are analyzed for trends and correlation calculations. The fault type is determined by combining the preset fault judgment rules. At the same time, the monitoring data of the pressure sensor and gas concentration sensor are processed simultaneously. The S5 cloud processing layer's user interaction module displays the device's real-time operating parameters and the fault determination results from the data analysis module in a visual format; if a fault is determined or the monitored parameters exceed the normal range, an alarm message is pushed.