LabVIEW-based data acquisition and monitoring system for press

Abstract

The present application relates to the technical field of industrial automation, and particularly relates to a press data acquisition and monitoring system based on LabVIEW; comprising a data acquisition module, a digital filtering algorithm module, a PID closed-loop control module, a data storage and management module, an alarm and safety module, an interaction module and a remote publishing module; wherein: the data acquisition module acquires signals; the digital filtering algorithm module performs noise suppression and smoothing processing on the acquired original signals; the PID closed-loop control module completes automatic adjustment operation according to the deviation between the set value and the measured value of the press; the data storage and management module performs high-speed writing, automatic file storage and historical data query on the press operation data; the alarm and safety module performs abnormal alarm, fault protection and program self-recovery on the press; multi-channel high-speed synchronous acquisition is realized, and there is no data packet loss, the system response is faster, the interface is not stuck, the operation is more stable, and the monitoring demand of high precision and high real-time of the press can be met.

Description

Technical Field

[0001] This invention relates to the field of industrial automation technology, and in particular to a press data acquisition and monitoring system based on LabVIEW. Background Technology

[0002] With the rapid advancement of Industry 4.0 and intelligent manufacturing, presses, as core equipment in industrial production and equipment manufacturing, require precise acquisition, real-time monitoring, and automatic control of key parameters such as pressure, displacement, temperature, and vibration during operation. This is crucial for ensuring safe equipment operation, improving product processing accuracy, and optimizing production processes. Currently, traditional press data acquisition and monitoring systems mostly adopt a hardware architecture centered on microcontrollers or PLCs, coupled with a simple human-machine interface to display basic data.

[0003] In existing technologies, the system adopts a single-threaded execution architecture, which leads to severe resource contention between data acquisition, interface updates, and logic control. This makes it impossible to achieve high-speed synchronous acquisition and real-time stable operation, and is prone to data loss, response delays, and interface lag. It is difficult to meet the high-precision and high-real-time monitoring requirements of modern presses. Summary of the Invention

[0004] The purpose of this invention is to provide a press data acquisition and monitoring system based on LabVIEW, which solves the problems of the single-threaded execution architecture, which leads to serious resource contention between data acquisition, interface updates, and logic control, making it impossible to achieve high-speed synchronous acquisition and real-time stable operation, and easily causing data loss, response lag, and interface lag, thus failing to meet the high-precision and high-real-time monitoring requirements of modern presses.

[0005] To achieve the above objectives, this invention employs a LabVIEW-based press data acquisition and monitoring system, comprising a data acquisition module, a digital filtering algorithm module, a PID closed-loop control module, a data storage and management module, an alarm and safety module, an interaction module, and a remote publishing module; wherein: The data acquisition module is used to perform high-speed synchronous acquisition of multi-channel analog / digital signals from the compressor via NI-DAQmx driver, and to complete signal conditioning, A / D conversion and data buffering. The digital filtering algorithm module is used to suppress and smooth the acquired raw signal, eliminating power frequency interference and random noise in the industrial field. The PID closed-loop control module is used to perform automatic adjustment calculations based on the deviation between the press set value and the measured value, and output control quantities to drive the actuator. The data storage and management module is used to complete high-speed writing of press operation data, automatic file-based storage, and historical data query in TDMS format; The alarm and safety module is used to perform multi-level threshold judgment, abnormal alarm, fault protection and program self-recovery on the compressor operating parameters; The interactive module is used for visualizing the compressor's operating status, configuring parameters, displaying operation responses and logs; The remote publishing module is used to publish the press's collected data and monitoring interface to the outside world via the network.

[0006] Furthermore, the data acquisition module includes a sensor signal access unit, a DAQmx drive control unit, and a multi-channel synchronous acquisition unit; wherein: The sensor signal access unit is used to connect displacement sensors, pressure transmitters and Hall sensors, and outputs a 4~20mA pressure signal to complete signal isolation, amplification and filtering conditioning. The DAQmx driver control unit is used to configure the acquisition channel, sampling rate, buffer and trigger mode, perform continuous sampling, and monitor the hardware status in real time. The multi-channel synchronous acquisition unit is used for synchronous acquisition through 8 analog inputs, 4 analog outputs and 16 digital I / Os.

[0007] Furthermore, the digital filtering algorithm module includes a moving average filtering unit, a Butterworth low-pass filtering unit, and a dynamic parameter adjustment unit; wherein: The moving average filtering unit is used to smooth random noise by calculating a fixed window mean. The Butterworth low-pass filter unit is used to filter out 50Hz power frequency interference in the industrial environment and retain the effective working signal of the press. The dynamic parameter adjustment unit is used to automatically switch the filtering mode and filtering order according to the on-site noise intensity.

[0008] Furthermore, the PID closed-loop control module includes a deviation calculation unit, a PID calculation unit, and a parameter tuning unit; wherein: The deviation calculation unit is used to acquire the press setpoint SP and process value PV in real time and calculate the control deviation. The PID calculation unit is used to output a 0~10V control quantity based on proportional, integral and derivative algorithms to control the regulating valve and frequency converter. The parameter tuning unit is used to adapt to different inertial loads of the press.

[0009] Furthermore, the data storage and management module includes a TDMS file writing unit, an automatic file allocation unit, and a historical data query unit; wherein: The TDMS file writing unit is used to write high-speed storage data in binary streaming mode, embedding metadata such as sensor name, unit, and timestamp. The automatic file splitting unit is used to automatically split data files according to a fixed time interval / fixed file size; The historical data query unit is used to retrieve historical data by time and channel number, export it, and connect it to MATLAB and DIAdem for offline analysis.

[0010] Furthermore, the alarm and security module includes a multi-level threshold judgment unit, an audible and visual alarm unit, and a watchdog self-recovery unit; wherein: The multi-level threshold judgment unit is used to set warning thresholds and fault thresholds. A yellow warning is triggered when the parameter exceeds the threshold by 90%, and a red fault is triggered when the parameter exceeds the threshold. The sound and light alarm unit is used for interface flashing, pop-up prompts and external sound and light output, and automatically cuts off the corresponding output channel when a fault occurs. The watchdog self-recovery unit is used to monitor the main loop operation status and automatically restart the data acquisition task if the blockage timeout occurs.

[0011] Furthermore, the human-computer interaction module includes a status display unit, a real-time curve unit, and an event response unit; wherein: The status display unit is used to display the system running / stopping, communication status, sampling rate, CPU usage, and current time. The real-time curve unit is used for synchronous display of multi-channel waveforms, displaying dashboard values, and comparing and scaling curves. The event response unit is used for event structure processing, parameter modification, and threshold configuration.

[0012] Furthermore, the remote network publishing module includes a Web service publishing unit, a data transmission unit, and a remote access unit; wherein: The Web service publishing unit is used to publish the monitoring interface and real-time data to the local area network and wide area network. The data transmission unit is used for encrypted data transmission via the MQTT protocol; The remote access unit is used to remotely view the press status on PC and mobile devices, modify parameters, query history, and receive alarm information.

[0013] This invention discloses a LabVIEW-based press data acquisition and monitoring system. The data acquisition module uses an NI-DAQmx driver to perform high-speed synchronous acquisition of multi-channel analog / digital signals from the press, completing signal conditioning, A / D conversion, and data buffering. The digital filtering algorithm module performs noise suppression and smoothing on the acquired raw signals, eliminating industrial frequency interference and random noise. The PID closed-loop control module performs automatic adjustment calculations based on the deviation between the press setpoint and measured values, and outputs control signals to drive the actuators. The data storage and management module stores press operation data in TDMS format. The system features high-speed writing, automatic file storage, and historical data querying; the alarm and safety module performs multi-level threshold judgment, abnormal alarms, fault protection, and program self-recovery for the press's operating parameters; the interaction module visualizes the press's operating status, configures parameters, displays operation responses, and logs; and the remote publishing module publishes the press's collected data and monitoring interface to the outside world via the network. Using these methods, multi-channel high-speed synchronous acquisition with zero data loss is achieved, resulting in faster system response, smoother interface, and more stable operation. This significantly improves the real-time performance and control accuracy of press monitoring, meeting the high-precision and high-real-time monitoring requirements of presses. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the press data acquisition and monitoring system based on LabVIEW according to the present invention.

[0016] Figure 2 This is a schematic diagram of the data acquisition module of the present invention. Figure 3 This is a schematic diagram of the digital filtering algorithm module of the present invention. Figure 4 This is a schematic diagram of the PID closed-loop control module of the present invention. Figure 5 This is a schematic diagram of the data storage and management module of the present invention. Figure 6 This is a schematic diagram of the alarm and safety module of the present invention. Figure 7 This is a schematic diagram of the interactive module of the present invention.

[0017] Figure 8 This is a schematic diagram of the remote publishing module of the present invention.

[0018] 100-Data Acquisition Module, 200-Digital Filtering Algorithm Module, 300-PID Closed-Loop Control Module, 400-Data Storage and Management Module, 500-Alarm and Security Module, 600-Interaction Module, 700-Remote Publishing Module, 101-Sensor Signal Access Unit, 102-DAQmx Drive Control Unit, 103-Multi-Channel Synchronous Acquisition Unit, 201-Moving Average Filtering Unit, 202-Butterworth Low-Pass Filtering Unit, 203-Dynamic Parameter Adjustment Unit, 301-Offset Differential calculation unit, 302-PID calculation unit, 303-parameter tuning unit, 401-TDMS file writing unit, 402-automatic file division unit, 403-historical data query unit, 501-multi-level threshold judgment unit, 502-audio-visual alarm unit, 503-watchdog self-recovery unit, 601-status display unit, 602-real-time curve unit, 603-event response unit, 701-Web service publishing unit, 702-data transmission unit, 703-remote access unit. Detailed Implementation

[0019] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0020] Please see Figures 1-8 This invention provides a LabVIEW-based press data acquisition and monitoring system, comprising a data acquisition module, a digital filtering algorithm module, a PID closed-loop control module, a data storage and management module, an alarm and safety module, an interaction module, and a remote publishing module; wherein: The data acquisition module is used to perform high-speed synchronous acquisition of multi-channel analog / digital signals from the compressor via NI-DAQmx driver, and to complete signal conditioning, A / D conversion and data buffering. The digital filtering algorithm module is used to suppress and smooth the acquired raw signal, eliminating power frequency interference and random noise in the industrial field. The PID closed-loop control module is used to perform automatic adjustment calculations based on the deviation between the press set value and the measured value, and output control quantities to drive the actuator. The data storage and management module is used to complete high-speed writing of press operation data, automatic file-based storage, and historical data query in TDMS format; The alarm and safety module is used to perform multi-level threshold judgment, abnormal alarm, fault protection and program self-recovery on the compressor operating parameters; The interactive module is used for visualizing the compressor's operating status, configuring parameters, displaying operation responses and logs; The remote publishing module is used to publish the press's collected data and monitoring interface to the outside world via the network.

[0021] In this embodiment, the data acquisition module uses the NI-DAQmx driver to perform high-speed synchronous acquisition of multi-channel analog / digital signals from the press, completing signal conditioning, A / D conversion, and data caching. The digital filtering algorithm module performs noise suppression and smoothing on the acquired raw signals, eliminating power frequency interference and random noise in the industrial environment. The PID closed-loop control module performs automatic adjustment calculations based on the deviation between the press setpoint and the measured value, and outputs control quantities to drive the actuator. The data storage and management module completes high-speed writing of press operating data in TDMS format, automatic file storage, and historical data query. The alarm and safety module performs multi-level threshold judgment, abnormal alarm, fault protection, and program self-recovery for press operating parameters. The interaction module visualizes the press operating status, configures parameters, displays operation responses, and logs. The remote publishing module publishes the press acquisition data and monitoring interface to the outside world via the network. By adopting the above methods, high-speed synchronous acquisition of multiple channels with zero data loss is achieved, the system response is faster, the interface is smooth, and the operation is more stable, significantly improving the real-time performance and control accuracy of press monitoring, and meeting the high-precision and high-real-time monitoring requirements of the press.

[0022] Furthermore, the data acquisition module includes a sensor signal access unit, a DAQmx drive control unit, and a multi-channel synchronous acquisition unit; wherein: The sensor signal access unit is used to connect displacement sensors, pressure transmitters and Hall sensors, and outputs a 4~20mA pressure signal to complete signal isolation, amplification and filtering conditioning. The DAQmx driver control unit is used to configure the acquisition channel, sampling rate, buffer and trigger mode, perform continuous sampling, and monitor the hardware status in real time. The multi-channel synchronous acquisition unit is used for synchronous acquisition through 8 analog inputs, 4 analog outputs and 16 digital I / Os.

[0023] In this embodiment, the sensor signal access unit connects to a displacement sensor, a pressure transmitter, and a Hall sensor, outputting a 4~20mA pressure signal to complete signal isolation, amplification, and filtering conditioning; the DAQmx drive control unit configures the acquisition channels, sampling rate, buffer, and triggering mode to perform continuous sampling and monitor the hardware status in real time; the multi-channel synchronous acquisition unit supports 8 analog inputs, 4 analog outputs, and 16 digital I / Os for synchronous acquisition.

[0024] Furthermore, the digital filtering algorithm module includes a moving average filtering unit, a Butterworth low-pass filtering unit, and a dynamic parameter adjustment unit; wherein: The moving average filtering unit is used to smooth random noise by calculating a fixed window mean. The Butterworth low-pass filter unit is used to filter out 50Hz power frequency interference in the industrial environment and retain the effective working signal of the press. The dynamic parameter adjustment unit is used to automatically switch the filtering mode and filtering order according to the on-site noise intensity.

[0025] In this embodiment, the moving average filtering unit smooths random noise by calculating the mean value of a fixed window; the Butterworth low-pass filtering unit filters out 50Hz power frequency interference in the industrial environment while retaining the effective working signal of the press; and the dynamic parameter adjustment unit automatically switches the filtering mode and filtering order according to the noise intensity at the site.

[0026] Furthermore, the PID closed-loop control module includes a deviation calculation unit, a PID calculation unit, and a parameter tuning unit; wherein: The deviation calculation unit is used to acquire the press setpoint SP and process value PV in real time and calculate the control deviation. The PID calculation unit is used to output a 0~10V control quantity based on proportional, integral and derivative algorithms to control the regulating valve and frequency converter. The parameter tuning unit is used to adapt to different inertial loads of the press.

[0027] In this embodiment, the deviation calculation unit acquires the press setpoint SP and process value PV in real time and calculates the control deviation; the PID calculation unit outputs a 0~10V control quantity based on proportional, integral, and derivative algorithms to control the regulating valve and frequency converter; and the parameter tuning unit adapts to different inertial loads of the press.

[0028] Furthermore, the data storage and management module includes a TDMS file writing unit, an automatic file allocation unit, and a historical data query unit; wherein: The TDMS file writing unit is used to write high-speed storage data in binary streaming mode, embedding metadata such as sensor name, unit, and timestamp. The automatic file splitting unit is used to automatically split data files according to a fixed time interval / fixed file size; The historical data query unit is used to retrieve historical data by time and channel number, export it, and connect it to MATLAB and DIAdem for offline analysis.

[0029] In this embodiment, the TDMS file writing unit writes high-speed storage data in binary streaming mode, embedding metadata such as sensor name, unit, and timestamp; the automatic file splitting unit automatically splits the data file according to a fixed time interval / fixed file size; and the historical data query unit retrieves historical data by time and channel number, exports it, and interfaces it with MATLAB and DIAdem for offline analysis.

[0030] Furthermore, the alarm and security module includes a multi-level threshold judgment unit, an audible and visual alarm unit, and a watchdog self-recovery unit; wherein: The multi-level threshold judgment unit is used to set warning thresholds and fault thresholds. A yellow warning is triggered when the parameter exceeds the threshold by 90%, and a red fault is triggered when the parameter exceeds the threshold. The sound and light alarm unit is used for interface flashing, pop-up prompts and external sound and light output, and automatically cuts off the corresponding output channel when a fault occurs. The watchdog self-recovery unit is used to monitor the main loop operation status and automatically restart the data acquisition task if the blockage timeout occurs.

[0031] In this embodiment, the multi-level threshold judgment unit sets a warning threshold and a fault threshold. A yellow warning is triggered when the parameter exceeds the threshold by 90%, and a red fault is triggered when the parameter exceeds the threshold. The sound and light alarm unit displays a flashing interface, pop-up prompts, and external sound and light outputs. In case of a fault, the corresponding output channel is automatically cut off. The watchdog self-recovery unit monitors the main loop operation status and automatically restarts the acquisition task if the blockage timeout occurs.

[0032] Furthermore, the human-computer interaction module includes a status display unit, a real-time curve unit, and an event response unit; wherein: The status display unit is used to display the system running / stopping, communication status, sampling rate, CPU usage, and current time. The real-time curve unit is used for synchronous display of multi-channel waveforms, displaying dashboard values, and comparing and scaling curves. The event response unit is used for event structure processing, parameter modification, and threshold configuration.

[0033] In this embodiment, the status display unit displays the system running / stopping status, communication status, sampling rate, CPU usage, and current time; the real-time curve unit synchronously displays multi-channel waveforms, shows dashboard values, and compares and zooms the curves; the event response unit handles event structure processing, parameter modification, and threshold configuration.

[0034] Furthermore, the remote network publishing module includes a Web service publishing unit, a data transmission unit, and a remote access unit; wherein: The Web service publishing unit is used to publish the monitoring interface and real-time data to the local area network and wide area network. The data transmission unit is used for encrypted data transmission via the MQTT protocol; The remote access unit is used to remotely view the press status on PC and mobile devices, modify parameters, query history, and receive alarm information.

[0035] In this embodiment, the Web service publishing unit publishes the monitoring interface and real-time data to the local area network and wide area network; the data transmission unit encrypts and transmits data via the MQTT protocol; and the remote access unit remotely views the compressor status, modifies parameters, queries history, and receives alarm information via PC and mobile devices.

[0036] The above description discloses only one preferred embodiment of the present invention, and should not be construed as limiting the scope of the present invention. Those skilled in the art will understand that all or part of the processes of the above embodiments can be implemented, and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A press data acquisition and monitoring system based on LabVIEW, characterized in that, It includes a data acquisition module, a digital filtering algorithm module, a PID closed-loop control module, a data storage and management module, an alarm and security module, an interaction module, and a remote publishing module; among which: The data acquisition module is used to perform high-speed synchronous acquisition of multi-channel analog / digital signals from the compressor via NI-DAQmx driver, and to complete signal conditioning, A / D conversion and data buffering. The digital filtering algorithm module is used to suppress and smooth the acquired raw signal, eliminating power frequency interference and random noise in the industrial field. The PID closed-loop control module is used to perform automatic adjustment calculations based on the deviation between the press set value and the measured value, and output control quantities to drive the actuator. The data storage and management module is used to complete high-speed writing of press operation data, automatic file-based storage, and historical data query in TDMS format; The alarm and safety module is used to perform multi-level threshold judgment, abnormal alarm, fault protection and program self-recovery on the compressor operating parameters; The interactive module is used for visualizing the compressor's operating status, configuring parameters, displaying operation responses and logs; The remote publishing module is used to publish the press's collected data and monitoring interface to the outside world via the network.

2. The press data acquisition and monitoring system based on LabVIEW as described in claim 1, characterized in that, The data acquisition module includes a sensor signal access unit, a DAQmx drive control unit, and a multi-channel synchronous acquisition unit; wherein: The sensor signal access unit is used to connect displacement sensors, pressure transmitters and Hall sensors, and outputs a 4~20mA pressure signal to complete signal isolation, amplification and filtering conditioning. The DAQmx driver control unit is used to configure the acquisition channel, sampling rate, buffer and trigger mode, perform continuous sampling, and monitor the hardware status in real time. The multi-channel synchronous acquisition unit is used for synchronous acquisition through 8 analog inputs, 4 analog outputs and 16 digital I / Os.

3. The press data acquisition and monitoring system based on LabVIEW as described in claim 1, characterized in that, The digital filtering algorithm module includes a moving average filtering unit, a Butterworth low-pass filtering unit, and a dynamic parameter adjustment unit; wherein: The moving average filtering unit is used to smooth random noise by calculating a fixed window mean. The Butterworth low-pass filter unit is used to filter out 50Hz power frequency interference in the industrial environment and retain the effective working signal of the press. The dynamic parameter adjustment unit is used to automatically switch the filtering mode and filtering order according to the on-site noise intensity.

4. The press data acquisition and monitoring system based on LabVIEW as described in claim 1, characterized in that, The PID closed-loop control module includes a deviation calculation unit, a PID calculation unit, and a parameter tuning unit; wherein: The deviation calculation unit is used to acquire the press setpoint SP and process value PV in real time and calculate the control deviation. The PID calculation unit is used to output a 0~10V control quantity based on proportional, integral and derivative algorithms to control the regulating valve and frequency converter. The parameter tuning unit is used to adapt to different inertial loads of the press.

5. The press data acquisition and monitoring system based on LabVIEW as described in claim 1, characterized in that, The data storage and management module includes a TDMS file writing unit, an automatic file allocation unit, and a historical data query unit; wherein: The TDMS file writing unit is used to write high-speed storage data in binary streaming mode, embedding metadata such as sensor name, unit, and timestamp. The automatic file splitting unit is used to automatically split data files according to a fixed time interval / fixed file size; The historical data query unit is used to retrieve historical data by time and channel number, export it, and connect it to MATLAB and DIAdem for offline analysis.

6. The press data acquisition and monitoring system based on LabVIEW as described in claim 1, characterized in that, The alarm and security module includes a multi-level threshold judgment unit, an audible and visual alarm unit, and a watchdog self-recovery unit; wherein: The multi-level threshold judgment unit is used to set warning thresholds and fault thresholds. A yellow warning is triggered when the parameter exceeds the threshold by 90%, and a red fault is triggered when the parameter exceeds the threshold. The sound and light alarm unit is used for interface flashing, pop-up prompts and external sound and light output, and automatically cuts off the corresponding output channel when a fault occurs. The watchdog self-recovery unit is used to monitor the main loop operation status and automatically restart the data acquisition task if the blockage timeout occurs.

7. The press data acquisition and monitoring system based on LabVIEW as described in claim 1, characterized in that, The human-computer interaction module includes a status display unit, a real-time curve unit, and an event response unit; wherein: The status display unit is used to display the system running / stopping, communication status, sampling rate, CPU usage, and current time. The real-time curve unit is used for synchronous display of multi-channel waveforms, displaying dashboard values, and comparing and scaling curves. The event response unit is used for event structure processing, parameter modification, and threshold configuration.

8. The press data acquisition and monitoring system based on LabVIEW as described in claim 1, characterized in that, The remote network publishing module includes a Web service publishing unit, a data transmission unit, and a remote access unit; wherein: The Web service publishing unit is used to publish the monitoring interface and real-time data to the local area network and wide area network. The data transmission unit is used for encrypted data transmission via the MQTT protocol; The remote access unit is used to remotely view the press status on PC and mobile devices, modify parameters, query history, and receive alarm information.

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