A fixed staff management system based on PLC control and terminal identification

Abstract

The application discloses a kind of based on PLC control+terminal identification's fixed staff management system.System has been increased two sets of control units in the upper layer of access control system management platform, respectively PLC1200 main control unit and upper computer backup control unit, two sets of control units are redundant structure, when a set of control unit is offline, another control unit can immediately run.System has strong anti-interference ability and stability, can effectively solve the fixed staff control problem of manufacturing enterprise workshop personnel and vehicle, strictly controls production site operation number, records the information of personnel, vehicle exit and entry in detail, improves the safety management level and management efficiency of enterprise, reduces the human resource cost of enterprise.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, specifically to a staffing management system based on PLC control and terminal identification. Background Technology

[0002] Manufacturing and other high-risk industries are characterized by labor intensity, complex processes, and diverse risks. Overcrowding of personnel and vehicles at production sites often leads to loss of control, frequent violations, and serious safety hazards. Accidents not only cause significant economic losses but also endanger employee lives and social stability. With the continuous strengthening of national safety production supervision requirements, enterprises urgently need to establish standardized safety production management systems and strictly fulfill their legal responsibilities. As densely populated and high-risk locations, the accurate control of on-site personnel numbers in manufacturing workshops has always been a core challenge and pain point in safety management, and the state has strict staffing requirements for high-risk production sites. Traditional management models relying on manual registration and inspections have revealed many fatal flaws in practice. First, the number of personnel is inaccurate; with numerous entrances and exits in production workshops, managers cannot obtain real-time and accurate information on the number of people on duty. Second, staffing standards are not strictly enforced; even when staffing standards are set, they are often broken due to factors such as rushing to meet deadlines and lax management, leading to overcrowding in high-risk areas. In the event of emergencies such as fires or explosions, congestion of evacuation routes can significantly exacerbate casualties. Furthermore, due to a lack of technical means, the paper-based staffing quota system has become a mere formality because it lacks effective technical constraints. Labor organization is chaotic, and outsiders can freely enter and exit, rendering safety regulations ineffective.

[0003] Currently, most manufacturing and other hazardous industries have large production areas. For ease of management, entrances and exits are relatively centralized, and staffing management still relies on traditional methods, such as access control and registration. Access control and registration are highly susceptible to subjective human factors, resulting in low management efficiency. Chinese patent CN203573331U describes a real-time staffing management system for industrial explosives production based on RFID. This system uses high-frequency RFID for entrance and exit identification and ultra-high-frequency RFID readers for real-time on-site monitoring. While suitable for smaller production sites, its identification, access control, and counting are controlled by a host computer and slave computers. However, its stability is poor in harsh production environments, posing certain safety hazards. Furthermore, RFID devices suffer from low identification efficiency and lack uniqueness, leading to issues such as borrowing, theft, and loss. The patent CN215068386U, a non-contact personnel management and monitoring device, uses four cameras deployed at entrances and exits for personnel management—two for counting and two for identification. However, this camera identification technology lacks access control capabilities and cannot effectively manage personnel, allowing for unauthorized entry. Moreover, the identification cameras are susceptible to interference from weather, dust, and other factors, resulting in significant counting errors. The patent CN101847276A, a personnel management system and method, proposes a system consisting of a control unit, an alarm processing unit, an identification acquisition unit located at the entrance, and a counting sensing unit. While this patent outlines the composition and general method of the personnel management system, it does not provide a specific implementation path.

[0004] In addition, industrial environments such as manufacturing sites are extremely harsh, with serious dust, vibration, electromagnetic interference, power fluctuations and other factors that can cause system restarts, shutdowns or even damage; conventional staffing control equipment is difficult to operate stably in such environments. Summary of the Invention

[0005] Based on the above-mentioned technical problems, this invention proposes a staffing management system based on PLC control and terminal identification to solve the problem of overstaffing in harsh production environments such as industrial manufacturing, and to strictly control the number of workers and vehicles on the production site.

[0006] To address the aforementioned technical problems, one objective of this invention is to provide a staffing management system based on PLC control and terminal identification. This system comprises a PLC1200 main control unit 1, a host computer backup control unit 2, a communication gateway 3, a convergence switch 4, a management platform 5, pedestrian barriers 6, and vehicle barriers 10. The PLC1200 main control unit 1 is used to realize the staff counting and issue the gate opening command; The host computer backup control unit 2 is used for human-computer interaction, authorization management, real-time monitoring of entry and exit status, and entry and exit log management. It also has the functions of personnel counting and barrier gate switch control. It communicates with the PLC1200 main control unit 1 in real time to jointly complete the main and backup redundancy control of the system. The communication gateway 3 is used to realize the communication protocol conversion between the PLC1200 main control unit and the management platform 5, that is, to parse the data uploaded by the management platform 5 and encapsulate the data sent by the PLC1200 main control unit 1. The management platform 5 is a dedicated server for the access control system, used to manage and analyze captured photos of devices such as gates, facial recognition terminals, and license plate recognition cameras in the access control system.

[0007] Furthermore, the PLC1200 main control unit 1 and communication gateway 3 are deployed in the control cabinet of the workshop, low-voltage room or control room.

[0008] Furthermore, the aggregation switch 4 and management platform 5 are deployed in the cabinet of the control room, and the pedestrian gate 6 and vehicle gate 10 are deployed at the corresponding entrances and exits of the workshop, and can be expanded according to the number of entrances and exits on site.

[0009] Furthermore, the pedestrian barrier 6 consists of an access switch 7, an internal face recognition terminal 8, and an external face recognition terminal 9.

[0010] Furthermore, the vehicle barrier gate 10 consists of an access switch 11, an internal license plate recognition camera 12, and an external license plate recognition camera 13.

[0011] The above-described one or more technical solutions of the present invention have at least one or more of the following technical effects: This system should be able to monitor entry and exit status in real time and accurately control the number of personnel and vehicles within the production area, eliminating safety risks caused by overstaffing at the source. Simultaneously, it should automate the registration and management of personnel and vehicles entering and exiting, creating a traceable and verifiable electronic ledger. This not only helps improve the standardization of on-site management and effectively prevent safety accidents, but also optimizes production organization through orderly scheduling, improving overall operational efficiency while ensuring safety.

[0012] This invention adds two control units to the existing access control system. These units not only enable real-time display of personnel information entering the workshop, entry and exit log recording, and personnel management via a host computer, but also feature redundant control capabilities and low cost. Furthermore, using a Siemens PLC1200 industrial controller as the main control unit ensures strong stability and reliability. Secondly, compared to RFID card-swiping authorization, facial recognition offers a more convenient and rapid response, effectively preventing card lending and loss. Combined with a turnstile, it enables precise personnel identification, significantly improving workshop management efficiency and accuracy. In addition, the number of entrance and exit channels depends on the management platform. With sufficient interfaces on the management platform, simply connecting the turnstiles to the platform expands the number of entrance and exit channels, demonstrating high scalability, applicability, and promotional value. Attached Figure Description

[0013] Figure 1 System control flowchart; Figure 2 System architecture diagram.

[0014] Among them: 1-PLC1200 main control unit, 2-upper computer backup control unit, 3-communication gateway, 4-aggregation switch, 5-management platform, 6-pedestrian barrier gate, 7-access switch one, 8-face recognition terminal (inner), 9-face recognition terminal (outer), 10-vehicle barrier gate, 11-access switch two, 12-license plate recognition camera (inner), 13-license plate recognition camera (outer). Detailed Implementation

[0015] This invention designs a personnel management system based on a PLC control and terminal identification system, using an access control system as its foundation. The system adds two control units to the upper layer of the access control system management platform: a PLC1200 main control unit and a host computer backup control unit. These two control units are redundant; when one control unit goes offline, the other can immediately take over. This allows for stable operation in harsh environments and effective control of the number of people and vehicles on the production site. Simultaneously, it records personnel and vehicle entry and exit information, improving the enterprise's safety management level and efficiency while reducing safety management costs.

[0016] This staffing management system is based on an access control system. It adds a PLC1200 main control unit for staff counting and a backup control unit on the upper layer of its management platform. The door opening control function of the management platform is removed and migrated to the two control units to determine whether to open the gate based on whether the workshop is overcrowded. Staffing control can be achieved through a simple modification of the access control system. It has a simple structure, low cost, and high application value.

[0017] The PLC1200 is used as the main controller to control the staffing logic, ensuring strong system stability and adaptability to various harsh industrial environments. In addition, the host computer not only enables human-machine interaction, registration management, personnel display within the workshop, access log recording, and historical query functions, but also has the capability to communicate with the PLC1200 in real time to achieve redundant control, further enhancing the system's stability and reliability. The system authorizes entry and exit from the workshop based on facial recognition and license plate recognition, which is faster, more accurate, and more convenient than other authorization methods, effectively preventing problems such as loss, theft, or misuse of authorization media.

[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments and accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments obtained. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0019] The overall workflow of the staffing management system is shown in the attached figure. Figure 1 As shown. The personnel management system includes vehicle and personnel personnel management functions, with similar control logic. Upon initial system startup, personnel information needs to be initialized by entering authorized personnel information, photos, and license plate information into the host computer, and setting the personnel quota. Then, normal entry and exit to the workshop can be achieved through facial recognition or license plate recognition. When a facial recognition terminal or license plate recognition camera located inside or outside the entrance / exit gate captures facial or license plate information, it is immediately uploaded to the system for analysis. Simultaneously, the system determines the entry / exit status based on the terminal location. If it is in an "exit" state, the gate is opened to allow passage; if it is in an "entry" state, it checks whether the person or vehicle is registered and authorized. If authorized, it further checks whether the controlled area is overloaded. If not overloaded, the gate is opened to allow entry; otherwise, an "unauthorized" voice prompt is given. If overloaded, a "overloaded" voice prompt is given directly. Finally, the system updates the personnel and vehicle data within the controlled area based on the entry / exit status.

[0020] The staffing management system of the present invention is as follows: Figure 2 As shown, the system of this invention consists of a PLC1200 main control unit 1, a host computer backup control unit 2, a communication gateway 3, an aggregation switch 4, a management platform 5, a pedestrian barrier 6, and a vehicle barrier 10. The pedestrian barrier 6 consists of an access switch 7, an internal face recognition terminal 8, and an external face recognition terminal 9; the vehicle barrier 10 consists of an access switch 11, an internal license plate recognition camera 12, and an external license plate recognition camera 13.

[0021] Specifically, the PLC1200 main control unit 1 and communication gateway 3 are deployed in control cabinets in the workshop, low-voltage room, or control room. Depending on the industry, they can also be deployed in explosion-proof electrical cabinets that meet the requirements. The aggregation switch 4 and management platform 5 are deployed in the cabinet in the control room. Pedestrian barriers 6 and vehicle barriers 10 are deployed at the corresponding entrances and exits of the workshop, and can be expanded according to the number of entrances and exits on site. The entire network communicates via Ethernet. The PLC1200 main control unit 1 is used to implement personnel counting and issue barrier opening commands. The host computer backup control unit 2 is used for human-machine interaction, authorization management, real-time monitoring of entry and exit status, and entry and exit log management. It also has personnel counting and barrier opening / closing functions, and together with the PLC1200 main control unit 1, they jointly complete the main / backup redundancy control of the system. The communication gateway 3 is used to implement the communication protocol conversion between the PLC1200 main control unit and the management platform 5, that is, to parse the data uploaded by the management platform 5 and encapsulate the data sent by the PLC1200 main control unit 1. Management Platform 5 is a dedicated server for access control systems, used to manage and analyze captured images of devices such as gates, facial recognition terminals, and license plate recognition cameras in traditional access control systems.

[0022] Furthermore, when a pedestrian or vehicle enters the workshop, the facial recognition terminal 9 or license plate recognition camera 13 captures a real-time photo and uploads it to the management platform 5 for analysis. This retrieves the authorized personnel or vehicle information, which is then packaged and pushed via the communication gateway 3 to the PLC1200 main control unit 1 and the upper-level backup control unit 2 for personnel counting. Upon receiving the data, the PLC1200 main control unit 1 determines if the workshop is overcrowded. If not, it records key information and sends an opening command to the management platform 5 via the communication gateway 3; otherwise, it sends a "refuse to open" command and simultaneously sends an overcrowding voice broadcast command to the management platform 5. The management platform 5 then forwards the command to the corresponding facial recognition terminal or license plate recognition camera. During the data push process from the management platform 5 to the two control units, the upper-level backup control unit 2 sends a heartbeat signal to the PLC1200 main control unit 1 in real time. If the PLC1200 main control unit 1 fails to respond, it immediately takes over the data pushed by the management platform 5 and responds, thus achieving redundant control for personnel management. In addition, the backup control unit 2 of the host computer synchronizes the workshop personnel information with the PLC1200 main control unit in real time, and queries the database to update the display interface and entry / exit logs. The process of leaving the workshop is similar to that of entering the workshop, at which time the facial recognition terminal and license plate recognition camera are internal devices.

[0023] Obviously, those skilled in the art can make various modifications and variations to the embodiments of the present invention without departing from the spirit and scope of the embodiments of the present invention. Thus, if these modifications and variations to the embodiments of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention also intends to include these modifications and variations.

Claims

1. A staffing management system based on PLC control and terminal identification, characterized in that: The system consists of a PLC1200 main control unit (1), a host computer backup control unit (2), a communication gateway (3), a convergence switch (4), a management platform (5), a pedestrian barrier (6), and a vehicle barrier (10). The PLC1200 main control unit (1) is used to realize the counting of personnel and the issuance of gate opening commands; The host computer backup control unit (2) is used for human-computer interaction, authorization management, real-time monitoring of entry and exit status, and entry and exit log management. It also has the functions of staff counting and gate switch control. It communicates with the PLC1200 main control unit (1) in real time to jointly complete the main and backup redundancy control of the system. The communication gateway (3) is used to realize the communication protocol conversion between the PLC1200 main control unit and the management platform (5), that is, to parse the data uploaded by the management platform (5) and encapsulate the data sent by the PLC1200 main control unit (1); The management platform (5) is a dedicated server for access control systems, used to complete the unified management and photo capture analysis of devices such as gates, face recognition terminals, and license plate recognition cameras in traditional access control systems.

2. The staffing management system based on terminal identification according to claim 1, characterized in that: The PLC1200 main control unit (1) and communication gateway (3) are deployed in the control cabinet of the workshop, low-voltage room or control room.

3. The staffing management system based on terminal identification according to claim 1, characterized in that: The aggregation switch (4) and management platform (5) are deployed in the cabinet of the control room. The pedestrian gate (6) and vehicle gate (10) are deployed at the corresponding entrances and exits of the workshop, and can be expanded according to the number of entrances and exits on site.

4. The staffing management system based on terminal identification according to claim 1, characterized in that: The pedestrian barrier (6) consists of an access switch (7), an internal face recognition terminal (8), and an external face recognition terminal (9).

5. The staffing management system based on terminal identification according to claim 1, characterized in that: The vehicle barrier gate (10) consists of an access switch (11), an internal license plate recognition camera (12), and an external license plate recognition camera (13).

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