A closed space operation tool inventory and anti-missing alarm system and method

Abstract

The application discloses a closed space operation tool counting and anti-missing alarm system and method, and relates to the field of tool management. The system comprises: a tool with an electronic identification tag; a detection access control device arranged at an entrance and exit, which comprises an RFID reader, a direction recognition sensor group composed of a first sensor and a second sensor, a logic judgment unit; a central control alarm platform; and an automatic interception mechanism. The method comprises: determining the in-out direction through double-sensor time sequence, triggering the reader to read the tag; comparing the in-out list on the platform; and alarming and starting physical interception when the number is not matched. The application can automatically identify the in-out of tools, accurately determine the direction, effectively eliminate interference, and timely alarm and physically intercept when tools are missing, thereby eliminating safety hazards.

Description

Technical Field

[0001] This invention relates to the field of power construction safety monitoring and tool management technology. Specifically, it relates to an intelligent system for automatically counting, identifying, and alarming if tools are not taken out when workers enter the enclosed spaces of power equipment such as generator stators, turbine condensers, and boiler drums for installation, maintenance, and cleaning during the construction of power plants. Background Technology

[0002] During the construction, installation, and commissioning phases of a power plant, workers frequently need to carry various tools such as wrenches, screwdrivers, torque wrenches, welding torches, and testing instruments into the generator stator to perform critical tasks such as core assembly, winding inspection, and foreign object removal. As a core power generation device, if any metal tools or debris are left inside the generator stator, it may lead to catastrophic accidents such as stator core damage and winding insulation breakdown during subsequent rotor installation and high-speed rotation, resulting in huge economic losses and project delays.

[0003] Currently, power construction sites commonly manage tools and equipment through manual inventory checks, such as using tool lists, inspection tags, or centralized tool kits. However, this method has the following inherent drawbacks: 1. High rate of human error: The internal structure of the generator stator is complex, the working space is narrow, and it often involves cross-operations and multiple shifts. Personnel enter and exit frequently, and there are many types of tools. Relying on manual counting one by one is very easy to miss or make mistakes, especially when rushing to meet the deadline or working continuously at night.

[0004] 2. Lack of proactive alarm mechanism: Existing management methods rely on the sense of responsibility of personnel. If a tool is left inside the stator, the system cannot proactively issue an alarm. It will only be passively discovered when a problem occurs during the equipment startup or debugging phase, by which time the consequences are often irreversible.

[0005] While existing technologies have developed solutions for tool management using RFID technology, these solutions face specific technical bottlenecks when applied to complex industrial scenarios such as power plant construction: Inaccurate direction determination: At the generator stator manhole, a single RFID reader can only read the presence of the tag and cannot distinguish whether a tool was brought in or taken out. When personnel repeatedly enter and exit the narrow manhole, such as peering in, passing tools, or moving their bodies in and out, it can easily lead to duplicate counting or misjudgment of direction.

[0006] Lack of anti-interference logic: When tools (especially metal tools) pass through manholes, they may experience temporary signal loss or misreading due to shaking, obstruction, or proximity to metal walls. Without intelligent logic filtering, such interference signals will directly lead to mismatches in the entry and exit lists, triggering frequent false alarms and severely impacting normal construction progress. Summary of the Invention

[0007] The purpose of this invention is to provide a tool inventory and anti-loss alarm system specifically designed for use in enclosed spaces during power construction. This system can automatically identify the tool, accurately record its direction of entry and exit, compare it with the inventory list in real time, and proactively issue warnings when a tool is missing, thereby eliminating the risk of tools being left inside critical equipment such as generator stators.

[0008] To achieve the above objectives, the present invention provides the following technical solution: A system and method for inventorying and preventing the loss of tools and equipment used in confined spaces, comprising: Multiple tools with electronic tags, each tool having a unique electronic tag attached.

[0009] An entrance detection and access control device is installed at a single entrance or exit point, such as a generator stator manhole or equipment flange opening. The entrance detection and access control device includes: The orientation recognition sensor group consists of a first infrared sensor (A) and a second infrared sensor (B) spaced apart along the channel direction, used to accurately sense the movement direction of personnel and tools; wherein, the first infrared sensor (A) is located on the outside of the channel (away from the stator side), and the second infrared sensor (B) is located on the inside of the channel (close to the stator side). RFID readers are installed around gantry or manholes to read electronic identification tags on all tools passing through the entrance / exit when a valid entry / exit event occurs. The logic judgment unit is electrically connected to the first infrared sensor (A), the second infrared sensor (B) and the RFID reader (201), and is used to receive the trigger signals of the sensors and perform timing analysis, determine the direction of movement based on the analysis results, and trigger the RFID reader (201) to read the tag information when it is determined to be a valid entry or a valid exit. Furthermore, the logic judgment unit is communicatively connected to the central control alarm platform (300) to report the determined entry and exit events to the central control alarm platform (300) in real time and to receive parameter configuration instructions issued by the platform.

[0010] The central control alarm platform is communicatively connected to the entrance detection access control device (200), specifically including: Connected to an RFID reader (201) for receiving read tag information; It is connected to the logic judgment unit to receive entry and exit event information; Used to record and compare the entry and exit lists, and to issue an alarm command when the quantity brought in and the quantity taken out do not match; Used to issue parameter configuration instructions to the logic judgment unit.

[0011] An automatic interception mechanism, electrically connected to the central control alarm platform, is installed at the exit of the work isolation area. It is activated upon receiving an alarm command from the central control alarm platform to prevent personnel from leaving the work isolation area.

[0012] Furthermore, the logical judgment unit includes: The timing analysis module is used to detect the order and time interval between the triggering of the first infrared sensor (A) and the second infrared sensor (B); The direction determination module is used to determine whether the movement direction is entering, exiting, or invalid interference based on whether the order and time interval are within the preset normal passage time range. The trigger module is used to send a trigger signal to the RFID reader when a valid entry or exit is determined.

[0013] Furthermore, the electronic identification tag is an anti-metal RFID tag.

[0014] Furthermore, the central control alarm platform includes a display unit with a visual interface, which includes a tool list area, an entry / exit count panel area, and an alarm information bar area.

[0015] Furthermore, the first infrared sensor (A) and the second infrared sensor (B) are electrically connected to the input terminal of the logic judgment unit via signal lines; the logic judgment unit is electrically connected to the RFID reader via a control bus; the RFID reader is connected to the central control alarm platform via a data communication network; and the central control alarm platform is electrically connected to the automatic interception mechanism via a control line. Beneficial effects

[0016] Compared with the prior art, the present invention has the following significant advantages: 1. Prevent major equipment accidents: Fundamentally prevent catastrophic accidents such as rotor damage and insulation breakdown caused by tools left inside key equipment such as generator stators, and ensure the safety of core equipment in power construction projects; 2. Strong anti-interference capability: Through time window filtering mechanism and sequence integrity judgment, it effectively identifies and eliminates false triggers caused by abnormal passage behaviors such as personnel probes, tool shaking, and lingering, avoids false counting, and improves the stability and reliability of the system; 3. Full-process automated management: Replaces manual registration, realizes automated and information-based management of the entry and exit of tools and equipment, improves the management efficiency and intelligence level of power construction sites, makes data traceable, and clarifies responsibilities; 4. Proactive physical interception: The system works in conjunction with an automatic interception mechanism to automatically prevent personnel from leaving the isolation area when a tool is detected as missing. This physically eliminates the possibility of tools being left in confined spaces, elevating safety management from "post-incident alarm" to "real-time interception" and significantly reducing the risk of accidents. 5. High system reliability: All components work together through clear electrical connections and communication protocols. The direct electrical connection between the sensor and the logic judgment unit ensures microsecond-level trigger response, and the control bus between the logic judgment unit and the RFID reader avoids interference that may exist in wireless communication. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the system of the present invention, showing the generator stator, manhole passage, sensor layout and the connection relationship of each component; Figure 2 This is a schematic diagram of the structure of the tools and electronic identification tags in this invention; Figure 3 This is a logical timing diagram for the direction identification of the present invention; wherein: Figure 3 (a) is a sequence diagram of the entry action, showing the logic process in which the system determines a valid entry and triggers RFID reading when the first sensor is triggered first, the second sensor is triggered later, and the time interval between the two triggers is within the normal passage time range. In the diagram, t0 represents the time when the first sensor is triggered, t1 represents the time when the second sensor is triggered, t2 represents the time when the first sensor is reset, and t3 represents the time when the second sensor is reset; Figure 3 (b) is a timing diagram of the exit action, showing the logic process of the system determining a valid exit and triggering RFID reading when the second sensor is triggered first, the first sensor is triggered later, and the time interval between the two triggers is within the normal passage time range. In the diagram, t0 represents the time when the second sensor is triggered, t1 represents the time when the first sensor is triggered, t2 represents the time when the second sensor is reset, and t3 represents the time when the first sensor is reset; Figure 3 (c) is the anti-interference logic timing diagram, which shows the logic process of the system determining invalid interference and keeping the RFID silent when the trigger sequence is incomplete or the time interval between two triggers exceeds the normal passage time range.

[0018] In the figure, t0, t1, t2, t3, t4, and t5 represent sensor triggering and reset events at different times.

[0019] Figure 4 This is a schematic diagram of the interface of the central control alarm platform of the present invention.

[0020] Explanation of reference numerals in the attached figures Detailed Implementation

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0022] Hardware implementation In one specific embodiment of the present invention, each component is implemented using the following hardware: The logic judgment unit (203) uses an STM32F103 series microcontroller. Its PA0 pin is electrically connected to the output of the first infrared sensor (A), and its PA1 pin is electrically connected to the output of the second infrared sensor (B). The program embedded in the microcontroller performs timing analysis on the input signals of the two pins. When a preset trigger sequence is detected, a trigger pulse is sent to the RFID reader (201) through the PB0 pin. At the same time, data communication is performed with the central control alarm platform (300) through the USART serial port.

[0023] RFID reader (201): It adopts an ultra-high frequency RFID reader module with a working frequency of 920-925MHz. It is connected to the central control alarm platform (300) through the RS485 interface and receives the trigger signal of the logic judgment unit (203) through the I / O interface.

[0024] Central control alarm platform (300): It adopts an industrial control computer, is equipped with dedicated management software, and communicates with the detection access control device (200) via Ethernet.

[0025] Automatic interception mechanism (500): It adopts an electric gate and is connected to the central control alarm platform (300) via a relay. Example

[0026] At the construction site of a 2×1000MW coal-fired power generating unit, the generator stator has been hoisted into place. The installation personnel need to enter the stator to carry out the final cleaning and inspection work before the iron core magnetization test.

[0027] 1. Preparation stage All specialized tools used in the stator (including 8 torque wrenches of different sizes, 5 anti-magnetic wrenches, 2 inspection flashlights, and 1 end cap sealant applicator, totaling 16 items) are equipped with weather-resistant, anti-metal RFID tags (101). The system inputs the standard tool list for this operation via a handheld device and links it to the work order.

[0028] 2. Entering the stage The installers carried their tools to the stator manhole.

[0029] At time t0: The person at the front first blocks the first infrared sensor (A) installed on the outside of the manhole. The logic judgment unit (203) detects the change in the PA0 pin level, records "sensor A triggered", starts the timing, and the system enters the expected count state.

[0030] At time t1: The person continues to enter, blocking the second infrared sensor (B) on the inside. The logic judgment unit (203) detects the change in the PA1 pin level.

[0031] At time t2: The logic judgment unit (203) detects the complete trigger sequence of "A before B", and the time interval between the two triggers is within the preset normal passage time range, thus determining it as a valid entry action. It then sends a trigger pulse to the RFID reader (201) via the PB0 pin, waking the RFID reader (201) to read the tag. The RFID reader (201) instantly reads the information of all 16 tools carried by the person and uploads it to the central control alarm platform (300) via the RS485 bus.

[0032] At time t3: Personnel have fully entered, the second infrared sensor (B) resumes illumination, and the entry process ends.

[0033] After receiving the data, the central control alarm platform (300) updates the "Current Internal Tool List" for the work area to 16 items, such as... Figure 4 As shown, the list (N) is displayed. - (in=16), and displays the specific tool name and number.

[0034] 3. Work Phase During the operation, a person poked their head out of the manhole, their body blocking the inner sensor B, but they quickly retracted without blocking the outer sensor A. The logic judgment unit (203) detected that only B was triggered and that no trigger signal from A was received within the preset normal passage time. It determined this to be interference, and the system automatically reset, without triggering any counting or reading, thus avoiding erroneous "exit" records.

[0035] 4. Exit Phase The work was completed, and the personnel returned with their tools.

[0036] At time t0: Personnel exit from the inside, first blocking the second infrared sensor (B) on the inside. The logic judgment unit (203) detects the change in the PA1 pin level, records "sensor B triggered", and starts timing.

[0037] At time t1: Personnel continue to move outward, blocking the first infrared sensor (A) on the outside. The logic judgment unit (203) detects the change in the PA0 pin level.

[0038] At time t2: The logic judgment unit (203) detects the complete trigger sequence of "B before A", and the time interval between the two triggers is within the preset normal passage time range, thus determining it as a valid exit action. It then sends a trigger pulse to the RFID reader (201) via the PB0 pin, waking the RFID reader (201) to read the tags. The RFID reader (201) reads the information of 15 tools and uploads it to the platform.

[0039] At time t3: Personnel have completely exited the area, the second infrared sensor (B) resumes illumination, and the exit process is complete.

[0040] Central control alarm platform (300) automatic comparison: 16 items were brought in, 15 items were brought out, such as Figure 4 As shown, the list to be brought out (N) is displayed. - The system will display the name and number of the missing tool (out=15), and indicate the name and number of the missing tool. The system will immediately trigger a sharp audible and visual alarm and pop up a red warning window on the monitoring screen: "Tool missing! Missing item: Anti-magnetic wrench (ID: F005)".

[0041] The central control alarm platform (300) sends a start command to the automatic interception mechanism (500) through the relay output, and the electric gate set at the exit of the isolation area immediately closes, prohibiting personnel from leaving.

[0042] 5. Handling Supervisors instructed personnel to halt their departure via broadcast and then search inside the stator. The accidentally dropped antimagnetic wrench was eventually found inside. Personnel then exited through the manhole with the wrench. The system detected that the number of tools taken out had increased to 16. After the platform confirmed the match, it sent a release command to the automatic interception mechanism (500), unlocking the gate and completing the operation loop.

[0043] 6. Handling Interference Situations If people peek out from the entrance or exit, move their tools around, or linger or loiter, the following situations may occur: Only one sensor was triggered, while the other was not. Two sensors were triggered, but the time interval exceeded the normal passage time range; The sensor triggering sequence is abnormal (e.g., it is triggered first, then reset, and then triggered again). The system was not reset in the correct order after being triggered.

[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A system and method for inventorying and preventing the omission of tools and equipment used in confined spaces, characterized in that, include: Multiple electronic identification tags attached to tools and equipment; A detection access control device installed at the entrance / exit of a confined space, the detection access control device comprising: RFID reader / writer used to read information from electronic identification tags; A direction recognition sensor group for sensing the direction of movement of personnel and tools, the direction recognition sensor group consists of a first sensor and a second sensor that are spaced apart along the channel direction; A logic judgment unit electrically connected to the first and second sensors; The central control alarm platform is connected in communication with the detection access control device and is used to record and compare the list of tools and equipment used to enter and leave the enclosed space. An automatic interception mechanism, electrically connected to the central control alarm platform, is installed at the exit of the work isolation zone; The logical judgment unit is used for: The direction of movement is determined by the order in which the first and second sensors are triggered and the time interval between them. When a valid entry or exit is determined, the RFID reader is triggered to read the electronic tag information. The central control alarm platform is used for: Receive tag information read by RFID reader and generate inbound and outbound lists; When the number of tools and identification information at the time of departure does not match the information at the time of entry, an alarm command is issued and the automatic interception mechanism is activated.

2. The system and method for inventorying and preventing the omission of tools and equipment in confined spaces according to claim 1, characterized in that, The logic judgment unit is specifically used for: When the first sensor is detected to be triggered before the second sensor, and the time interval between the two triggers is within the preset normal passage time range, the direction of movement is determined to be entering; When the second sensor is detected to be triggered before the first sensor, and the time interval between the two triggers is within the preset normal passage time range, the movement direction is determined to be exit; If the time interval between two triggers exceeds the preset normal passage time range, or if the trigger sequence is incomplete, it is determined to be invalid interference and is not counted in the entry / exit count.

3. The system and method for inventorying and preventing the omission of tools and equipment in confined spaces according to claim 1, characterized in that, The first sensor and the second sensor are infrared through-beam sensors, wherein the first sensor is located on the outside of the channel and the second sensor is located on the inside of the channel.

4. The system and method for inventorying and preventing the omission of tools and equipment in confined spaces according to claim 1, characterized in that, The electronic identification tag is an anti-metal RFID tag.

5. The system and method for inventorying and preventing the omission of tools and equipment in confined spaces according to claim 1, characterized in that, The central control alarm platform includes a display unit with a visual interface, which includes a tool list area, an entry / exit count panel area, and an alarm information bar area.

6. A system and method for inventorying and preventing the omission of tools and equipment used in confined spaces, based on any one of claims 1-5, comprising the following steps: S1: Attach a unique electronic identification tag to the tool or equipment and enter the initial information into the central control alarm platform; S2: The movement of personnel and tools is detected by the first and second sensors of the access control device. The logic judgment unit determines the direction of entry and exit according to the sensor triggering sequence and time interval. When it is determined to be a valid entry, the RFID reader is triggered to read the electronic identification tag information and generate an entry list N_in. S3: When personnel leave, the first and second sensors of the access control device are used to detect the direction of movement. When the logic judgment unit determines that the exit is valid, the RFID reader is triggered to read the electronic tag information and generate a departure list N_out. S4: The central control alarm platform compares N_in with N_out; S5: If N_in ≠ N_out, the central control alarm platform will trigger an alarm command and control the automatic interception mechanism to start, preventing personnel from leaving the work isolation area; S6: After the missing tool is found and re-detected by the access control device, the central control alarm platform will deactivate the alarm command and control the automatic interception mechanism to restore passage.

7. A system and method for inventorying and preventing the omission of tools and equipment used in confined spaces according to claim 6, characterized in that, In steps S2 and S3, the conditions for the logic judgment unit to determine a valid entry or valid exit include: The sensor triggering sequence follows an entry or exit pattern, meaning that when entering, the first sensor triggers before the second sensor, and when exiting, the second sensor triggers before the first sensor. The interval between the two triggers is within the preset normal passage time range; The trigger sequence is complete, meaning both sensors are triggered and reset in the normal order.

8. A system and method for inventorying and preventing the omission of tools and equipment used in confined spaces, as described in claim 6, is characterized in that... The method also includes an interference elimination step: When the logic judgment unit detects that only one sensor is triggered, the sensor triggering sequence is abnormal, or the sensor is not reset in the normal sequence after being triggered, it is determined to be invalid interference, the RFID reader remains silent, and is not counted in the entry and exit count.

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