A WIFI connection data collector

Abstract

The application relates to the technical field of data collectors, in particular to a WIFI connection data collector which comprises a data collection module, a WIFI communication module, a protocol conversion module and a main control module; the main control module is electrically connected with the data collection module, the WIFI communication module and the protocol conversion module; the collector is connected with a local area network through the WIFI communication module to establish a multi-device communication connection; the protocol conversion module is adapted to multiple industrial data protocols, bidirectional data interaction with PLC or external management software is realized, and digital management after data collection is completed. The application realizes multi-end synchronous data transmission, completely solves the limitation of WIFI single-device point-to-point connection, is matched with a signal amplification unit and a high-gain antenna, the communication distance in an unobstructed environment can reach 100 m, the communication distance in an obstructed industrial environment can reach 50 m, the transmission distance limitation of the WIFI protocol is broken through, the device is loaded with a special protocol conversion module, is adapted to multiple mainstream industrial protocols, and can be directly connected with PLC and industrial management software.

Description

Technical Field

[0001] This invention relates to the field of data acquisition technology, specifically a WIFI-connected data acquisition device. Background Technology

[0002] Data acquisition devices are core equipment for real-time data acquisition and transmission in industrial production and equipment monitoring. As a traditional acquisition device, the WIFI data acquisition device is used in small monitoring scenarios due to the convenience of wireless connection. Its core function is to realize wireless acquisition and single-end transmission of field equipment data, which is suitable for simple data monitoring scenarios with short distance and single device.

[0003] However, traditional WIFI data collectors have obvious technical defects: First, their connectivity is limited, and they can only achieve point-to-point communication with a single external device, which cannot meet the needs of industrial scenarios where multiple devices can acquire data at the same time. Secondly, the communication distance is limited. The transmission distance is limited by the WIFI protocol itself. The signal attenuation is severe beyond the short distance range, which cannot be adapted to long-distance data acquisition in large industrial sites. Third, the protocol compatibility is poor, there is no dedicated protocol conversion module, it cannot be directly connected to PLC and industrial management software, the collected data is difficult to achieve digital and systematic management, manual secondary transfer and processing is required, which is inefficient and prone to data errors.

[0004] In summary, a WIFI-connected data collector is needed to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a WIFI-connected data collector to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: This invention proposes a WIFI connection data collector, including a data acquisition module, a WIFI communication module, a protocol conversion module, and a main control module; The main control module is electrically connected to the data acquisition module, the WIFI communication module, and the protocol conversion module, respectively. The collector establishes a multi-device communication connection by connecting to the local area network via a WIFI communication module. The protocol conversion module is compatible with multiple industrial data protocols, enabling bidirectional data interaction with PLCs or external management software, and completing digital management after data acquisition.

[0007] Preferably, the implementation process of the data acquisition module is as follows: acquire the raw data of the device to be monitored, perform preprocessing operations such as filtering, noise reduction and format standardization on the raw data in sequence, and transmit the preprocessed standard data to the main control module in real time. The preprocessed standard data meets the data rate and accuracy requirements of WIFI network transmission.

[0008] Preferably, the implementation process of the WIFI communication module is as follows: receiving standard data issued by the main control module, initiating a link establishment request based on the local area network WIFI communication protocol, establishing independent communication links with multiple external devices in the local area network, realizing bidirectional data transmission between the collector and each external device, and the transmission status of each communication link is monitored in real time by the main control module.

[0009] Preferably, the WIFI communication module has a built-in signal amplification unit, which performs power enhancement processing on the WIFI transmitted and received signals to match the communication distance of the collector with the WIFI signal coverage of the environment, thereby completing long-distance data transmission.

[0010] Preferably, the implementation process of the protocol conversion module is as follows: receiving standard data transmitted by the main control module, identifying the target docking device as a PLC or external management software, retrieving the preset corresponding data protocol, converting the standard data into protocol data that the target docking device can recognize, and completing the transmission; at the same time, receiving instruction data issued by the target docking device, converting the instruction data into a format that the main control module can recognize, and transmitting it to the main control module.

[0011] Preferably, the implementation process of the main control module is as follows: receiving standard data transmitted by the data acquisition module, performing integrity and validity checks on the standard data, temporarily caching the data after the checks are passed, and then transmitting the data to the WIFI communication module and the protocol conversion module respectively according to the preset scheduling rules; receiving instruction data from the protocol conversion module, parsing the instruction data and sending it to the corresponding functional modules to realize the collaborative work and data linkage of each module.

[0012] Preferably, the collector further includes a data storage module, which is electrically connected to the main control module. The data storage module receives standard data transmitted by the main control module and protocol data from the protocol conversion module, classifies and persistently stores the two types of data, and the stored data can be retrieved by the main control module and transmitted to external devices via the WIFI communication module.

[0013] Preferably, the overall implementation process of the data collector is as follows: The data acquisition module completes the raw data acquisition and preprocessing, and transmits the standard data to the main control module; After completing data verification and caching, the main control module distributes the data to the WIFI communication module, protocol conversion module and data storage module. The WIFI communication module enables data transmission between multiple devices on the local area network, the protocol conversion module completes protocol adaptation and data interaction with the PLC or external management software, and the data storage module completes local data storage and performs operations synchronously under the unified scheduling of the main control module.

[0014] A management system for a WIFI-connected data acquisition device includes a WIFI-connected data acquisition device, a local area network gateway, several external terminal devices, a PLC, and external management software. The WIFI-connected data acquisition device connects to an industrial local area network through the local area network gateway and establishes independent communication links with several external terminal devices. The WIFI-connected data acquisition device establishes data interaction channels with the PLC and external management software respectively through a protocol conversion module.

[0015] Preferably, the local area network gateway of the management system enables network adaptation between the WIFI-connected data collector and the industrial local area network. The PLC receives protocol data transmitted by the WIFI-connected data collector and executes corresponding device control commands. The external management software receives protocol data transmitted by the WIFI-connected data collector and performs data statistics and analysis. Several external terminal devices retrieve the collected and stored data from the WIFI-connected data collector through the industrial local area network. The WIFI-connected data collector receives commands issued by each terminal and provides feedback on the execution results.

[0016] Compared with existing technologies, the beneficial effects of this invention are as follows: Compared with traditional WIFI data collectors, the data collector of this invention achieves multi-dimensional technological upgrades, adapts to the actual application needs of industrial sites, supports up to 32 devices in a local area network to establish independent communication links simultaneously, realizes multi-terminal synchronous data transmission, and completely solves the limitation of single-device point-to-point connection of WIFI; equipped with a signal amplification unit and high-gain antenna, the communication distance can reach 100m in unobstructed environments and 50m in obstructed industrial environments, breaking through the transmission distance limitation of WIFI protocol; the device is equipped with a dedicated protocol conversion module, adapting to multiple mainstream industrial protocols, and can directly interface with PLC and industrial management software to realize direct digital management of collected data, avoiding errors and inefficiencies of manual secondary data transfer; at the same time, it adopts industrial-grade high-precision acquisition devices, with high acquisition and transmission accuracy and low packet loss rate; the modular architecture supports flexible parameter configuration, and also has local data storage and remote command interaction functions; the device is miniaturized and integrated, convenient to deploy, and greatly improves the efficiency of industrial data acquisition and intelligent management level. Attached Figure Description

[0017] Figure 1 This is a topology diagram of the data acquisition device for WIFI connection in this invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Please see Figure 1 This invention proposes a WIFI connection data collector, including a data acquisition module, a WIFI communication module, a protocol conversion module and a main control module; The main control module is electrically connected to the data acquisition module, the WIFI communication module, and the protocol conversion module, respectively. The data collector establishes a multi-device communication connection by connecting to the local area network via a WIFI communication module; The protocol conversion module is compatible with multiple industrial data protocols, enabling bidirectional data interaction with PLCs or external management software, and completing digital management after data acquisition.

[0020] It should also be noted that the implementation process of the data acquisition module is as follows: raw data from the device to be monitored is collected, and preprocessing operations such as filtering, noise reduction and format standardization are performed on the raw data in sequence. The preprocessed standard data is then transmitted to the main control module in real time. The preprocessed standard data meets the data rate and accuracy requirements of WIFI network transmission.

[0021] It should also be noted that the implementation process of the WIFI communication module is as follows: receiving standard data issued by the main control module, initiating a link establishment request based on the local area network WIFI communication protocol, establishing independent communication links with multiple external devices in the local area network, realizing bidirectional data transmission between the collector and each external device, and the transmission status of each communication link is monitored in real time by the main control module.

[0022] It should also be noted that the WIFI communication module has a built-in signal amplification unit. The signal amplification unit performs power enhancement processing on the WIFI transmitted and received signals, so that the communication distance of the collector matches the WIFI signal coverage of the environment, thus completing long-distance data transmission.

[0023] It should also be noted that the implementation process of the protocol conversion module is as follows: receiving standard data transmitted by the main control module, identifying the target docking device as a PLC or external management software, retrieving the preset corresponding data protocol, converting the standard data into protocol data that the target docking device can recognize, and completing the transmission; at the same time, receiving instruction data issued by the target docking device, converting the instruction data into a format that the main control module can recognize, and then transmitting it to the main control module.

[0024] It should also be noted that the implementation process of the main control module is as follows: receiving standard data transmitted by the data acquisition module, performing integrity and validity checks on the standard data, temporarily caching the data after the checks pass, and then transmitting the data to the WIFI communication module and the protocol conversion module respectively according to the preset scheduling rules; receiving instruction data from the protocol conversion module, parsing the instruction data and sending it to the corresponding functional modules to realize the collaborative work and data linkage of each module.

[0025] It should also be noted that the data collector also includes a data storage module, which is electrically connected to the main control module. The data storage module receives standard data transmitted by the main control module and protocol data from the protocol conversion module, classifies and persistently stores the two types of data, and the stored data can be retrieved by the main control module and transmitted to external devices through the WIFI communication module.

[0026] It should also be noted that the overall implementation process of the data collector is as follows: The data acquisition module completes the acquisition and preprocessing of raw data and transmits the standard data to the main control module; After the main control module completes data verification and caching, it distributes the data to the WIFI communication module, protocol conversion module, and data storage module. The WIFI communication module enables data transmission between multiple devices on the local area network, the protocol conversion module completes protocol adaptation and data interaction with the PLC or external management software, and the data storage module completes local data storage. All operations are executed synchronously under the unified scheduling of the main control module.

[0027] The present invention also proposes a management system for a WIFI-connected data acquisition device, including a WIFI-connected data acquisition device, a local area network gateway, several external terminal devices, a PLC and external management software. The WIFI-connected data acquisition device connects to an industrial local area network through the local area network gateway and establishes independent communication links with several external terminal devices. The WIFI-connected data acquisition device establishes data interaction channels with the PLC and external management software respectively through a protocol conversion module.

[0028] It should also be noted that the management system's LAN gateway enables network adaptation between the Wi-Fi connected data collector and the industrial LAN. The PLC receives protocol data transmitted by the Wi-Fi connected data collector and executes corresponding device control commands. The external management software receives protocol data transmitted by the Wi-Fi connected data collector and performs data statistics and analysis. Several external terminal devices retrieve the collected and stored data from the Wi-Fi connected data collector through the industrial LAN. The Wi-Fi connected data collector receives commands from each terminal and provides feedback on the execution results.

[0029] For examples and practical applications, please refer to the following: Figure 1 The WIFI-connected data collector of this invention consists of a main control module, a data acquisition module, a WIFI communication module, a protocol conversion module, a data storage module, and a power supply module. Each module is a commercially available standardized component. The electrical connections are as follows: the power supply module provides operating power to all other modules; the main control module is bidirectionally electrically connected to the data acquisition module, the WIFI communication module, the protocol conversion module, and the data storage module. The specific selection of each module is as follows: The main control module uses an STM32F407ZGT6 microcontroller with a main frequency of 168MHz, 1MB Flash and 192KB RAM, and supports multiple serial ports, SPI and I2C communication interfaces to realize unified scheduling and data interaction of various modules. The data acquisition module includes an analog acquisition unit AD7606 and a digital acquisition unit DIO-880. The AD7606 is a 16-bit 8-channel synchronous acquisition chip with an acquisition accuracy of ±0.01%. The DIO-880 supports 8 channels of digital input / output with a response time of ≤1ms. The WIFI communication module uses the ESP32-WROOM-32E module, which supports the IEEE802.11b / g / n WIFI protocol, 2.4G frequency band communication, built-in signal amplification unit PA, transmit power 20dBm, and receive sensitivity -97dBm; The protocol conversion module uses the USR-M100 industrial-grade protocol conversion module, which supports bidirectional conversion of mainstream industrial protocols such as Modbus RTU, Modbus TCP, Profinet, and OPC UA, and the serial port baud rate supports 1200-115200bps. The data storage module uses the W25Q128JV serial flash memory chip, with a storage capacity of 128Mbit, erase / write cycles of ≥100,000 times, and a data retention time of ≥20 years. It is connected to the main control module via the SPI interface. The power supply module uses the LM2596 switching power supply module, with an input voltage of 9-36V DC and a stable output of 5V / 3A DC. It has overvoltage, overcurrent, and short circuit protection functions and is suitable for industrial field power supply environments.

[0030] Each module is integrated into an aluminum alloy housing measuring 120mm×80mm×30mm. The housing has an IP65 dustproof and waterproof rating. The WIFI communication antenna is an external high-gain rod antenna with a gain of 5dBi. The protocol conversion module is equipped with a standard RJ45 network port and an RS485 serial port. The data acquisition module is equipped with 16 aviation plug acquisition interfaces. Detailed implementation method: The WIFI-connected data collector of this invention achieves data collection, transmission, protocol conversion, and digital management through the coordinated work of various modules. The specific workflow consists of seven steps, each executed in conjunction with the others, to complete data processing without interruption: Power supply initialization: Connect the power supply module to the industrial site 9-36V DC power supply. The LM2596 module will stabilize the voltage to 5V / 3A and supply power to all modules. Each module completes self-test and sends a ready signal to the main control module. After receiving all ready signals, the main control module enters the working state. If the self-test fails, the buzzer alarm will be triggered. The alarm frequency is 1 time / second. Data Acquisition and Preprocessing: The data acquisition module is connected to the sensor output of the device under monitoring via an aviation connector. The analog acquisition unit AD7606 acquires analog data at a preset frequency and converts it into digital signals after analog-to-digital conversion. The digital acquisition unit DIO-880 directly acquires digital signals. The acquisition module performs filtering, noise reduction, and format standardization on all signals in sequence. The filtering adopts a moving average filtering algorithm with a window size of 10. The noise reduction adopts an amplitude limiting filtering algorithm to remove abnormal data that exceeds the threshold. After standardization, the data is uniformly converted into JSON format and transmitted to the main control module in real time. Data verification and caching: The main control module receives standard data transmitted by the acquisition module and performs integrity and validity verification on the data. The verification rules are that the data fields are not missing and the data values ​​are within a preset reasonable range. After the verification is passed, the data is written to the data storage module for temporary caching. The caching time can be set. If the verification fails, the abnormal data is marked and fed back to the acquisition module, and the acquisition module re-acquires the corresponding data. Local Area Network (LAN) Multi-Device Link Establishment: Under the scheduling of the main control module, the WIFI communication module initiates a LAN connection request based on the IEEE 802.11n protocol, accesses the industrial site's 2.4G WIFI LAN, obtains a dynamic or static IP address, and establishes independent TCP communication links with multiple external terminal devices within the LAN. Each time a link is established, it reports the link status to the main control module. The main control module monitors the connection status of all links in real time. If a link is disconnected, it automatically initiates a reconnection, with a maximum of 3 reconnections. Protocol conversion and industrial equipment interfacing: The main control module transmits the verified standard data to the protocol conversion module. The protocol conversion module automatically identifies the target interfacing device type as a PLC or external management software, retrieves the preset corresponding industrial protocol, converts the standard data in JSON format into protocol data that the target device can recognize, and completes the data transmission through the RJ45 network port or RS485 serial port. Meanwhile, the protocol conversion module receives instruction data from the PLC or external management software, converts the instruction data into JSON format, and then transmits it to the main control module; Multi-terminal data transmission and local storage: The main control module transmits the cached data synchronously to all external terminal devices in the local area network through the established TCP communication link according to the preset scheduling rules. During the transmission, a data packetization strategy is adopted, with a packet size of 1024 bytes. At the same time, the data is written to the data storage module for persistent classification and storage. A storage directory is established according to the collection time and device number for easy retrieval later. Command parsing and execution: The main control module receives command data transmitted by the protocol conversion module, parses the command, identifies the command type as acquisition frequency adjustment, acquisition channel switching, data query or equipment control, and sends the parsed command to the corresponding functional module. Each module executes the command and feeds back the execution result to the main control module. The main control module feeds back the execution result to the external terminal device and the industrial docking device through the WIFI communication module and the protocol conversion module respectively, completing one command interaction.

[0032] The WIFI-connected data acquisition device of this invention can be configured with parameters according to the actual needs of the industrial site. All parameters are set through the host computer configuration software of the main control module. After configuration, the parameters are stored in the data storage module and are not lost when power is off. The core application parameters are divided into three categories: module operation parameters, communication parameters, and acquisition parameters. The specific parameter ranges and optimal values ​​are as follows: Data acquisition module: Analog signal acquisition frequency: 1Hz-100Hz, with an optimal value of 20Hz; Analog signal acquisition range: 0-5V, 0-10V, 4-20mA selectable, compatible with different types of sensors; Digital signal acquisition response thresholds: high level ≥ 3.3V, low level ≤ 0.8V; Abnormal data removal threshold: ±5% reasonable range, which can be customized.

[0033] WIFI communication module: WIFI communication frequency band: 2.4 GHz (IEEE 802.11b / g / n); Serial port baud rates: 9600bps, 19200bps, 115200bps, with the optimal value being 115200bps; Transmission rate: up to 300Mbps, with an optimal value of 54Mbps for actual industrial applications; Local area network connection method: DHCP dynamic IP or static IP is optional. Static IP network segments are adapted to industrial field local area networks (such as [192.168.1.xxx](192.168.1.xxx)). Maximum number of devices that can be connected simultaneously: ≤32, with an optimal value of 16 for industrial applications; Reconnection interval: 1s-5s, optimal value 2s.

[0034] Protocol conversion module: Mainstream protocol adaptation parameters: Modbus TCP port 502, Modbus RTU baud rate 9600bps, 8 data bits, 1 stop bit, none parity bit, Profinet communication rate 100Mbps, OPC UA port 4840; Protocol conversion delay: ≤50ms; Data forwarding frequency: consistent with the data acquisition frequency, adjustable from 1Hz to 100Hz.

[0035] Main control module and storage module: Main control module data processing rate: ≥1000 frames / second; Temporary cache time: 1 min - 60 min, optimal value 5 min; Persistent storage data overwrite rule: First-in, first-out; the earliest collected data is automatically overwritten when the storage capacity is full.

[0036] After the WIFI-connected data acquisition device of this invention is assembled and its parameters are configured, a comprehensive performance test is required. The test is conducted according to the general standards for industrial data acquisition equipment and the technical specifications of this invention. The test environment is a standard industrial environment (temperature -20℃ to 60℃, humidity 30%, no strong electromagnetic interference). The core test items, test methods, and qualification standards are as follows: Multi-device connectivity test: Connect the data collector to the industrial LAN, connect external terminal devices in sequence, and record the maximum number of stable connected devices. The qualified standard is that the maximum number of stable connections is ≥32, and there is no packet loss in the data transmission of a single device. Communication distance test: In both unobstructed and obstructed (industrial wall) environments, gradually increase the distance between the data collector and the wireless router to test the stability of data transmission. The pass standard is a communication distance ≥100m in an unobstructed environment and a communication distance ≥50m in an obstructed environment, with a signal strength ≥-70dBm. Data transmission accuracy and packet loss rate detection: A fixed-value signal is output through a standard signal source. The data collector collects the signal and transmits it to various external devices. The collected data is compared with the standard signal value to calculate the transmission accuracy. The number of data packets transmitted in one hour is counted to calculate the packet loss rate. The qualified standard is data transmission accuracy ≥ 99.9% and packet loss rate ≤ 0.01%. Protocol compatibility test: The data acquisition device was connected to Siemens S7-1200 PLC, Kunlun Tongtai Industrial Management Software, and Advantech OPC UA server respectively to test the smoothness of data upload and command issuance. The passing standard is to support bidirectional data interaction of Modbus RTU / TCP, Profinet, and OPC UA protocols, with a protocol conversion delay of ≤50ms. Acquisition accuracy test: The standard analog / digital signal source outputs signals of different ranges. After the acquisition device acquires the data, it compares the data with the standard value and calculates the acquisition accuracy. The qualified standard is analog acquisition accuracy ±0.01% and digital acquisition response time ≤1ms. Environmental adaptability test: The data acquisition device is placed in a high and low temperature test chamber (-20℃, 60℃) and a damp heat test chamber (85% humidity, 40℃) and run continuously for 24 hours to test the working status of the equipment. The pass standard is that the equipment is fault-free and the data acquisition and transmission are normal. Stability test: The data acquisition unit runs continuously for 720 hours without interruption to test the working status and data processing capabilities of each module. The passing standard is that the equipment does not crash or restart, and the data acquisition and transmission are uninterrupted.

[0037] The present invention relates to the practical application of a WIFI-connected data acquisition device in industrial production line equipment monitoring scenarios. Employing the optimal hardware selection and application parameters described in the above embodiments, the interface devices include a Siemens S7-1200 PLC (Modbus TCP protocol), 16 industrial field monitoring terminals, and MES production management software (OPC UA protocol). The devices to be monitored are production line motors, frequency converters, and temperature sensors. The specific operation and running results are as follows: S1. Hardware Assembly and Wiring: The modules are integrated into an aluminum alloy shell according to their electrical connection relationships. An external 5dBi high-gain WIFI antenna is provided. The data acquisition module is connected to the current sensor (4-20mA) of the production line motor, the speed sensor (0-10V) of the frequency converter, and the temperature sensor (0-5V) via an aviation plug. The protocol conversion module is connected to the industrial wireless router, Siemens S7-1200 PLC, and MES management software server via RJ45 network ports. The power supply module is connected to the 24V DC industrial power supply on the production line. S2. Parameter Configuration: The parameters of the data acquisition unit are set through the host computer configuration software. The analog signal acquisition frequency is 20Hz, and the acquisition ranges are 4-20mA, 0-10V, and 0-5V. The abnormal data rejection threshold is ±5%. The WIFI communication module uses a static IP ([192.168.1.100](192.168.1.100)), a baud rate of 115200bps, a transmission rate of 54Mbps, a maximum of 16 connected devices, and a reconnection interval of 2s. The protocol conversion module is configured with Modbus TCP port 502 and OPC UA port 4840, with a protocol conversion delay of 50ms. The main control module has a data processing rate of 1000 frames per second and a temporary buffer time of 5 minutes. S3. Equipment Start-up and Self-Test: After the power is connected, the power supply module outputs a stable 5V / 3A voltage. Each module completes its self-test and sends a ready signal to the main control module. The main control module enters the working state. There is no alarm information. The WIFI communication module successfully connects to the industrial 2.4G local area network and establishes an independent TCP communication link with 16 monitoring terminals. S4. Data Acquisition and Transmission: The data acquisition module collects motor current, inverter speed, and ambient temperature in real time. After filtering, noise reduction, and standardization, the data is converted into standard JSON format data and transmitted to the main control module. After the main control module completes the data verification (no missing data, no abnormalities), it temporarily caches the data and synchronously transmits it to 16 industrial field monitoring terminals. The terminals display the collected data in real time, with a data update frequency of 20Hz. S5. Protocol Conversion and Industrial Equipment Interoperability: The protocol conversion module recognizes that the Siemens S7-1200 PLC uses the Modbus TCP protocol and the MES management software uses the OPC UA protocol. It automatically retrieves the corresponding protocols and converts the standard JSON data into Modbus TCP and OPC UA protocol data respectively. The data is then transmitted to the PLC and MES management software via the RJ45 network port. The PLC uses the collected data to automatically control the production line equipment, and the MES management software performs statistics, analysis, and visualization of the collected data to complete the digital management of production data. S6. Local Storage and Command Interaction: The data acquisition unit stores all collected data in the W25Q128JV storage module according to the collection time and device number (motor, frequency converter, temperature sensor). The staff issues a collection frequency adjustment command (from 20Hz to 10Hz) through the MES management software. The command is converted by the protocol conversion module and transmitted to the main control module. The main control module parses the command and sends it to the data acquisition module. The acquisition module completes the parameter adjustment and feeds back the execution result to the MES management software. The entire command interaction process takes 30ms. S7. Performance test results: In this embodiment, the data collector stably connects to 16 external terminal devices, the wireless router has an unobstructed range of 80m, a signal strength of -65dBm, a data transmission accuracy of 99.95%, and a packet loss rate of 0.005%. Protocol conversion delay with PLC and MES management software is 40ms; analog signal acquisition accuracy is ±0.008%. The equipment ran continuously for 720 hours without crashes or restarts, and data acquisition and transmission were uninterrupted, fully meeting the actual needs of monitoring equipment in industrial production lines.

[0038] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A WIFI-connected data collector, characterized in that, It includes a data acquisition module, a WIFI communication module, a protocol conversion module, and a main control module; The main control module is electrically connected to the data acquisition module, the WIFI communication module, and the protocol conversion module, respectively. The collector establishes a multi-device communication connection by connecting to the local area network via a WIFI communication module. The protocol conversion module is compatible with multiple industrial data protocols, enabling bidirectional data interaction with PLCs or external management software, and completing digital management after data acquisition.

2. The WIFI connection data collector according to claim 1, characterized in that, The implementation process of the data acquisition module is as follows: acquire the raw data of the device to be monitored, perform preprocessing operations such as filtering, noise reduction and format standardization on the raw data in sequence, and transmit the preprocessed standard data to the main control module in real time. The preprocessed standard data meets the data rate and accuracy requirements of WIFI network transmission.

3. A WIFI connection data collector according to claim 2, characterized in that, The implementation process of the WIFI communication module is as follows: receiving standard data sent by the main control module, initiating a link establishment request based on the local area network WIFI communication protocol, establishing independent communication links with multiple external devices in the local area network, realizing bidirectional data transmission between the collector and each external device, and the transmission status of each communication link is monitored in real time by the main control module.

4. A WIFI connection data collector according to claim 3, characterized in that, The WIFI communication module has a built-in signal amplification unit, which enhances the power of the WIFI transmitted and received signals, so that the communication distance of the collector matches the WIFI signal coverage of the environment, thus completing long-distance data transmission.

5. A WIFI connection data collector according to claim 4, characterized in that, The implementation process of the protocol conversion module is as follows: receiving standard data transmitted by the main control module, identifying the target docking device as a PLC or external management software, retrieving the preset corresponding data protocol, converting the standard data into protocol data that the target docking device can recognize, and completing the transmission; at the same time, receiving instruction data issued by the target docking device, converting the instruction data into a format that the main control module can recognize, and transmitting it to the main control module.

6. A WIFI connection data collector according to claim 5, characterized in that, The implementation process of the main control module is as follows: receiving standard data transmitted by the data acquisition module, performing integrity and validity checks on the standard data, temporarily caching the data after the checks are passed, and then transmitting the data to the WIFI communication module and the protocol conversion module respectively according to the preset scheduling rules; receiving instruction data from the protocol conversion module, parsing the instruction data and sending it to the corresponding functional modules to realize the collaborative work and data linkage of each module.

7. A WIFI connection data collector according to claim 6, characterized in that, The data collector also includes a data storage module, which is electrically connected to the main control module. The data storage module receives standard data transmitted by the main control module and protocol data from the protocol conversion module, classifies and persistently stores the two types of data, and the stored data can be retrieved by the main control module and transmitted to external devices via the WIFI communication module.

8. A WIFI connection data collector according to claim 7, characterized in that, The overall implementation process of the data collector is as follows: The data acquisition module completes the raw data acquisition and preprocessing, and transmits the standard data to the main control module; After completing data verification and caching, the main control module distributes the data to the WIFI communication module, protocol conversion module and data storage module. The WIFI communication module enables data transmission between multiple devices on the local area network, the protocol conversion module completes protocol adaptation and data interaction with the PLC or external management software, and the data storage module completes local data storage and performs operations synchronously under the unified scheduling of the main control module.

9. A management system applied to a WIFI-connected data collector according to any one of claims 1 to 8, characterized in that, The device includes a WIFI-connected data acquisition unit, a local area network gateway, several external terminal devices, a PLC, and external management software as described in any one of claims 1 to 8. The WIFI-connected data acquisition unit connects to an industrial local area network through the local area network gateway and establishes independent communication links with several external terminal devices. The WIFI-connected data acquisition unit establishes data interaction channels with the PLC and external management software respectively through a protocol conversion module.

10. The management system according to claim 9, characterized in that, The local area network gateway of the management system enables network adaptation between the WIFI-connected data collector and the industrial LAN. The PLC receives protocol data transmitted by the WIFI-connected data collector and executes corresponding device control commands. The external management software receives protocol data transmitted by the WIFI-connected data collector and performs data statistics and analysis. Several external terminal devices retrieve the collected and stored data from the WIFI-connected data collector through the industrial LAN. The WIFI-connected data collector receives commands from each terminal and feeds back the execution results.

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