Infrared image linkage control edge controller

Abstract

The utility model discloses an infrared image linkage control edge controller which comprises an infrared image capturing device, an image storage module, an image analysis processing module, a data communication module and a power supply module. The infrared image capture devices are installed above the to-be-monitored devices, and the capture area of one infrared image capture device covers one or more to-be-monitored devices; the infrared image capturing device captures an infrared image of the to-be-monitored device and sends the infrared image to the image storage module for storage, the image analysis processing module analyzes and processes the infrared image stored in the image storage module, and the device with the temperature exceeding a preset threshold value is judged. And the information of the equipment with the temperature exceeding the preset threshold value is sent to an external PLC control system through the data communication module, and the PLC control system controls the equipment with the temperature exceeding the preset threshold value to stop. According to the utility model, the problem of direct equipment linkage control after an infrared camera detects the overtemperature of industrial field equipment is solved.

Description

Technical Field

[0001] The utility model relates to an infrared image linkage control edge controller, belonging to the technical field of edge control. Background Art

[0002] The temperature of the equipment will be within a normal range during operation, but once an abnormality occurs, the overall temperature or local temperature of the equipment will exceed the normal range. The existing use of visible light images for equipment inspections in the production process has the advantages of low cost, little influence from distance, high resolution, rich color information, clear edge features, and easy feature extraction. However, visible light cannot intuitively display the temperature distribution of the image, and only effectively displays the contour information. Infrared images can well display the surface temperature distribution of the image. By fusing the two with effective algorithms, a clearer and more effective temperature distribution image can be obtained. The images obtained by traditional cameras that fuse infrared light and visible light are directly transmitted to the upper-end intelligent video screen via wired or wireless means, which can realize temperature monitoring, but the transmitted images are not well processed and applied. The following are some shortcomings of traditional control types according to classification:

[0003] (1) Traditional cameras do not have the function of customizing the monitoring area and dividing it into zones based on the equipment. Even when AI algorithms analyze the images generated by complex scenes, human intervention is still required to determine the equipment or fault location, making it impossible to know the exact fault location.

[0004] (2) The traditional over-temperature alarm system can only view alarm events and image information in the centralized control system, and cannot display information such as fault points and temperature values ​​in real time.

[0005] (3) The traditional infrared image linkage control system cannot be connected to the PLC points of the control system. The PLC control system cannot display detailed over-temperature alarm screens. Sensors are required to transmit the screens to the centralized control system and then manually analyze and divide the regional points. Finally, decisions are issued to the equipment control points. The event processing path is long and the cycle is long. In the face of some emergency situations, it is not possible to quickly handle them by combining the image points with the PLC points.

[0006] (4) Traditional control methods cannot achieve automatic decision-making. When over-temperature occurs, manual decision-making is required. In the face of serious over-temperature, the centralized control system is not linked with the emergency response process system, which poses a great threat to on-site safety. Utility Model Content

[0007] The technical problem to be solved by the utility model is to provide an infrared image linkage control edge controller, which solves the problem of directly performing equipment linkage control after the infrared camera detects that the industrial field equipment is over-temperature.

[0008] The utility model adopts the following technical solutions to solve the above technical problems:

[0009] An infrared image linkage control edge controller comprises an infrared image capturing device, an image storage module, an image analysis and processing module, a data communication module and a power module; the infrared image capturing device is installed above a device to be monitored, and a capturing area of ​​one infrared image capturing device covers one or more devices to be monitored; an output end of the infrared image capturing device is connected to an input end of the image storage module, an output end of the image storage module is connected to an input end of the image analysis and processing module, an output end of the image analysis and processing module is connected to an external PLC control system via a data communication module, and a power module supplies power to the infrared image capturing device, the image storage module, the image analysis and processing module and the data communication module;

[0010] The infrared image capturing device captures the infrared image of the device to be monitored and sends it to the image storage module for storage. The image analysis and processing module analyzes and processes the infrared image stored in the image storage module to determine the device whose temperature exceeds a preset threshold. For the device whose temperature exceeds the preset threshold, an alarm or shutdown instruction is generated according to the safety level of the device, and the alarm or shutdown instruction is sent to the external PLC control system through the data communication module. The external PLC control system sends an alarm message to the user or controls the device whose temperature exceeds the preset threshold to shut down.

[0011] As a preferred solution of the utility model, the infrared image capturing device is installed on a support frame above the device to be monitored, and the support frame is installed on the ceiling of the room where the device to be monitored is located.

[0012] As a preferred solution of the utility model, the infrared image capturing device is an infrared camera with a protective shell.

[0013] As a preferred solution of the present utility model, the image storage module is a solid state hard disk.

[0014] As a preferred solution of the utility model, the image analysis and processing module is a central processing unit with model number 10500H. The image analysis and processing module divides the infrared image stored in the image storage module into image blocks, so that one image block corresponds to only one device to be monitored, and the image blocks are corresponded one-to-one with the points of the device to be monitored, and the temperature of the image blocks is compared with a preset threshold value, so as to judge the device whose temperature exceeds the preset threshold value, and send the point information and temperature information of the device whose temperature exceeds the preset threshold value to the external PLC control system through the data communication module.

[0015] As a preferred solution of the utility model, the data communication module includes an RS485 communication expansion unit, an RJ communication expansion unit, a Type-C communication expansion unit and a PCI-E communication expansion unit; each communication expansion unit has the same external size and assembly structure, and has the same inter-unit data interaction and power supply standard interface; the image analysis and processing module communicates with the external PLC control system through the RS485 communication expansion unit.

[0016] As a preferred solution of the utility model, the power supply module includes an MCU control unit, an EMC protection unit, a voltage matching unit, an AC-C-DC unit, a DC-C-DC unit, a communication unit and an optical isolation unit; the MCU control unit interacts with the image analysis and processing module through an RS485 communication expansion unit.

[0017] Compared with the prior art, the utility model adopts the above technical solution and has the following technical effects:

[0018] The utility model designs an infrared image linkage control edge controller, which opens up the limitations of traditional infrared image linkage control in terms of function, solves the shortcomings of existing control methods, and adds edge control to the control method, which greatly shortens the event processing path and cycle. In the face of some emergency situations, the image points and PLC points are immediately combined to realize the action control of rapid equipment processing, which is beneficial to ensure equipment safety, production safety and personnel safety on site. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is the appearance structure diagram of the edge controller in the utility model;

[0020] Figure 2 This is a principle block diagram of an infrared image linkage control edge controller of the utility model;

[0021] Figure 3 It is a bus diagram of the image analysis and processing module in the utility model;

[0022] Figure 4 It is a block diagram of the data communication module in the utility model;

[0023] Figure 5 This is a block diagram of the power module in the utility model. DETAILED DESCRIPTION

[0024] The embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be interpreted as limiting the present invention.

[0025] The utility model proposes an infrared image linkage control edge controller, which is used to monitor the temperature of industrial field equipment in real time. When the equipment temperature exceeds a preset threshold, the equipment point information exceeding the preset threshold is sent to an external PLC control system in real time, and the PLC control system controls the corresponding equipment to shut down. Figure 1 This is the appearance structure diagram of the edge controller.

[0026] like Figure 2 As shown, an infrared image linkage control edge controller includes an infrared image capturing device and an edge controller. The infrared image capturing device includes: a protective shell and an infrared camera. The infrared camera is arranged in the protective shell. The protective shell is arranged on a supporting frame. The supporting frame is arranged on the ceiling.

[0027] The edge controller includes an image storage module, an image analysis and processing module, a data communication module and a power supply module.

[0028] The image storage module uses a solid state drive to receive video images captured by the infrared camera, and then stores the video and sends it to the image analysis and processing module.

[0029] The image analysis and processing module is used to divide the infrared image into grid areas and several image blocks to ensure that there is only one device in one image block. The image block is matched with the device points set in advance to form a corresponding relationship between the image block and the device point, and the image block temperature is monitored in real time. The image analysis and processing module is integrated in the CPU10500H. The CPU contains 2 i5-10500H CPUs with 6 cores, 12 threads and a maximum frequency of 2.50GHz, 2 memory channels, and supports deep learning functions. The total memory is 128G, 2 12G graphics cards, the designed memory is 512MB, DDR3 / 4 storage unit, and has redundant power supply. Figure 3 This is the bus diagram of the image analysis and processing module.

[0030] The data communication module is provided with a plurality of uniform expansion slots, which include a communication bus, a power supply bus, a coding pin and an indication module, and the same electrical signals between the plurality of slots are interconnected.

[0031] like Figure 4 As shown, the data communication module includes an RS485 communication expansion unit, an RJ communication expansion unit, a Type-C communication expansion unit, and a PCI-E communication expansion unit. Each communication expansion unit has the same external dimensions and assembly structure, and has the same standard interface for data interaction and power supply between units. The image analysis and processing module communicates with the external PLC control system through the RS485 communication expansion unit. The power MCU microcontroller unit interacts with the image analysis and processing module through the RS485 communication expansion unit.

[0032] The data communication module can send fault information to the PLC control system, display detailed fault information and images on the PLC control interface, and automatically trigger the corresponding video screen of the device to help operators capture and understand the actual situation on site in a timely manner. In the event of severe overtemperature, the PLC control system will issue instructions to directly control the corresponding equipment to shut down.

[0033] like Figure 5 As shown in the figure, the power module is mainly composed of an MCU control unit, an EMC protection unit, a voltage matching unit, an AC-C-DC unit, a DC-C-DC unit, a communication unit, and an optical isolation unit. The power module uses a standard interface for power supply, and the edge controller can be connected to multiple power modules. The power supply and output voltage and current are normal through the coordination of various units to ensure the normal operation of the edge controller.

[0034] The utility model proposes an infrared image linkage control edge controller based on equipment. In terms of function, the infrared camera monitors the temperature of each equipment in the workshop in real time, accurately transmits it to the edge controller in real time, and the infrared image linkage control edge controller realizes image grid partitioning, establishes the corresponding relationship between the equipment mechanical structure point and the grid, displays the point temperature value in real time, and performs real-time diagnosis of point overtemperature in real time according to the set temperature standard. If the overtemperature phenomenon occurs, the corresponding fault alarm information is generated, and the edge controller automatically generates an alarm or shutdown instruction according to the safety level requirements, and sends it to the corresponding PLC point. The PLC control system issues the control parameters of the equipment or even the shutdown instruction. In addition, when the infrared linkage control edge controller generates the fault point information, temperature value, and control decision instruction, it can be transmitted to the PLC control system and the scheduling system: in the PLC control system, the alarm information of the corresponding fault point can be viewed, the fault image screen automatically pops up, and when the overtemperature is serious, the set control instruction automatically shuts down; in the scheduling system, the corresponding fault point alarm information can also be viewed, triggering the scheduling event, and when the overtemperature is serious, triggering the emergency response process set in advance.

[0035] The utility model solves the problem of directly controlling the equipment linkage after the infrared camera detects that the industrial field equipment is overheated. Traditional infrared cameras can only realize the functions of regional monitoring and alarm, and cannot perform control operations on the field equipment after detecting overheating. The infrared image linkage control edge controller involved in the utility model can realize image partition processing, intelligently identify the fault point when the equipment is overheated, and generate equipment fault alarm information in the centralized control system. When a serious overheating event occurs, the PLC system is linked to directly control the shutdown of the equipment, and the emergency response process is automatically triggered. The function of the utility model is more powerful than the traditional infrared alarm control mechanism, and the accuracy of fault judgment is greatly improved compared with manual judgment. It provides a more efficient control method for equipment safety and is beneficial to production safety.

[0036] The above embodiments are only for illustrating the technical idea of ​​the present utility model, and cannot be used to limit the protection scope of the present utility model. Any changes made on the basis of the technical solution in accordance with the technical idea proposed by the present utility model shall fall within the protection scope of the present utility model.

Claims

1. An infrared image linkage control edge controller, characterized in that: It comprises an infrared image capturing device and an edge controller, wherein the edge controller comprises an image storage module, an image analysis and processing module, a data communication module and a power module; the infrared image capturing device is installed above the device to be monitored, and the capturing area of ​​one infrared image capturing device covers one or more devices to be monitored; the output end of the infrared image capturing device is connected to the input end of the image storage module, the output end of the image storage module is connected to the input end of the image analysis and processing module, the output end of the image analysis and processing module is connected to an external PLC control system via the data communication module, and the power module supplies power to the infrared image capturing device, the image storage module, the image analysis and processing module and the data communication module; The infrared image capturing device captures the infrared image of the device to be monitored and sends it to the image storage module for storage. The image analysis and processing module analyzes and processes the infrared image stored in the image storage module to determine the device whose temperature exceeds a preset threshold. For the device whose temperature exceeds the preset threshold, an alarm or shutdown instruction is generated according to the safety level of the device, and the alarm or shutdown instruction is sent to the external PLC control system through the data communication module. The external PLC control system sends an alarm message to the user or controls the device whose temperature exceeds the preset threshold to shut down.

2. The infrared image linkage control edge controller according to claim 1, characterized in that: The infrared image capturing device is installed on a support frame above the device to be monitored, and the support frame is installed on the ceiling of the room where the device to be monitored is located.

3. The infrared image linkage control edge controller according to claim 2, characterized in that: The infrared image capturing device is an infrared camera with a protective shell.

4. The infrared image linkage control edge controller according to claim 1, characterized in that: The image storage module is a solid state hard disk.

5. The infrared image linkage control edge controller according to claim 1, characterized in that: The image analysis and processing module is a central processing unit of model 10500H. The image analysis and processing module divides the infrared image stored in the image storage module into image blocks, so that one image block corresponds to only one device to be monitored, and the image blocks are matched one by one with the points of the devices to be monitored, and the temperature of the image blocks is compared with a preset threshold value, so as to judge the device whose temperature exceeds the preset threshold value, and send the point information and temperature information of the device whose temperature exceeds the preset threshold value to the external PLC control system through the data communication module.

6. The infrared image linkage control edge controller according to claim 1, characterized in that: The data communication module includes an RS485 communication expansion unit, an RJ communication expansion unit, a Type-C communication expansion unit and a PCI-E communication expansion unit; each communication expansion unit has the same external dimensions and assembly structure, and has the same inter-unit data interaction and power supply standard interface; the image analysis and processing module communicates with an external PLC control system through the RS485 communication expansion unit.

7. The infrared image linkage control edge controller according to claim 1, characterized in that: The power supply module includes an MCU control unit, an EMC protection unit, a voltage matching unit, an AC-C-DC unit, a DC-C-DC unit, a communication unit and an optical isolation unit; the MCU control unit interacts with the image analysis and processing module through an RS485 communication expansion unit.

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