Data acquisition and remote monitoring system of fruit juice production line

Abstract

The utility model provides a data acquisition and remote monitoring system of a fruit juice production line, and belongs to the technical field of production monitoring operation data acquisition. The system comprises an equipment layer, a sensing layer, a transmission layer and a management layer. The equipment layer comprises a plurality of production equipment, and each production equipment is used for generating corresponding production data; the sensing layer comprises a plurality of detection devices and is used for acquiring corresponding production data and uploading the production data to the transmission layer; the transmission layer is also communicated with the equipment layer and the management layer respectively; the production data of the equipment layer is acquired in real time through the sensing layer, and the production data is remotely transmitted to the management layer through the transmission layer, so that comprehensive acquisition and remote monitoring of the equipment data are realized, and managers are helped to make scientific decisions.

Description

Technical Field

[0001] The utility model belongs to the technical field of production operation data collection and monitoring, and in particular relates to a data collection and remote monitoring system for a juice production line. Background Art

[0002] The statements in this section merely provide background technical information related to the present invention and do not necessarily constitute prior art.

[0003] With the development of modern industry and the wave of digital transformation, companies have increasingly higher requirements for improving production efficiency, reducing costs and ensuring product quality. Traditional production lines can no longer meet modern production needs.

[0004] The production process of the existing juice production line mainly includes cleaning, pulping, juicing, initial blending, sterilization, ultrafiltration, centrifuge separation, re-blending, filling, etc. Most of the processes require manual intervention and supervision, and lack of comprehensive collection and monitoring of production data. There are problems such as difficulty in collecting production data, low efficiency, difficulty in supervision, high cost, easy omissions, and untimely discovery of production anomalies such as equipment failure. These problems seriously restrict the improvement of production efficiency and the guarantee of product quality.

[0005] The prior art discloses relevant detection mechanisms, including a feed detection mechanism, a liquid discharge detection mechanism, a concentration detection mechanism, a sterilization detection mechanism, a filling detection mechanism, and a discharge detection mechanism. The squeezing device and the detection mechanisms are connected to a control system. Although the squeezing, sterilization, filling, and discharge of juice are tested for production data, the following problems still exist:

[0006] 1. Unable to meet the needs of remote monitoring;

[0007] 2. The types of production data collected are few and the production data mastered is not comprehensive;

[0008] 3. Equipment failure is not discovered in a timely manner. Summary of the invention

[0009] The utility model aims to provide a data collection and remote monitoring system for a juice production line, so as to solve the technical problems of incomplete and untimely collection of production data of the existing production line and low production efficiency.

[0010] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0011] Includes device layer, perception layer, transmission layer and management layer;

[0012] The equipment layer includes a plurality of production equipment, each of which is used to generate corresponding production data;

[0013] The perception layer includes a variety of detection devices for acquiring the corresponding production data and uploading it to the transmission layer;

[0014] The transport layer also communicates with the device layer and the management layer respectively.

[0015] Furthermore, the management layer installs a data collection platform, and the data collection platform refers to a server of the data collection system software.

[0016] Furthermore, the transmission layer includes a PLC gateway, a serial port server and a DTU.

[0017] Furthermore, the equipment layer includes cleaning equipment, pulping equipment, juicing equipment, primary mixing equipment, sterilization equipment, ultrafiltration equipment, centrifuge separation equipment, re-mixing equipment and filling equipment.

[0018] Furthermore, corresponding types of sensors are installed on the cleaning equipment, pulping equipment, juicing equipment, primary mixing equipment, ultrafiltration equipment, and centrifuge separation equipment, and each sensor is connected to the transmission layer to upload the production data detected by the sensor to the management layer.

[0019] Furthermore, the cleaning equipment is equipped with a flow sensor;

[0020] The beating equipment is equipped with a temperature sensor;

[0021] The juice extraction device is equipped with a flow sensor;

[0022] The initial mixing equipment is equipped with a temperature sensor, a liquid level sensor and a conductivity sensor;

[0023] The ultrafiltration equipment is equipped with a temperature sensor and a liquid level sensor;

[0024] The centrifuge separation device is equipped with a flow sensor.

[0025] Furthermore, the sterilization equipment, the re-blending equipment, and the filling equipment are respectively connected to the transmission layer to upload the corresponding production data to the management layer.

[0026] Furthermore, the perception layer also includes a plurality of temperature and humidity sensors evenly distributed in the workshop, which are used to collect temperature and humidity data, and transmit the temperature and humidity data to the management layer through the transmission layer.

[0027] Furthermore, the equipment layer also includes electricity meters, gas meters and water meters.

[0028] Furthermore, the electric meter, gas meter and water meter transmit the real-time electricity consumption, gas consumption and water consumption data to the management layer through the transmission layer respectively.

[0029] The technical solution of the utility model has the following beneficial effects:

[0030] 1. The production data of the equipment layer is obtained in real time through the perception layer, and the production data is remotely transmitted to the management layer through the transmission layer, realizing the comprehensive collection and remote monitoring of equipment data, helping managers make scientific decisions.

[0031] 2. Realize the digitization, visualization and intelligence of the entire process of juice production to improve production efficiency and product quality.

[0032] 3. By adopting information technology such as the Internet of Things and artificial intelligence, effective collection and monitoring of production data in all links of juice production can be achieved, providing real-time monitoring of production data, improving the real-time and accuracy of data collection, and greatly reducing the dependence of data statistics on people.

[0033] 4. Realize equipment failure early warning push, timely discover faulty equipment, and greatly improve the operating efficiency of the juice production line.

[0034] Advantages of additional aspects of the present invention will be partially given in the following description, and partially become apparent from the following description, or be learned through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The illustrative embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation on the present invention.

[0036] Figure 1 This is a schematic diagram of the system structure of the utility model.

[0037] Figure 2 This is a schematic diagram of the connection between a cleaning device, a pulping device, a juice extraction device and a gateway in one embodiment of the utility model.

[0038] Figure 3 It is a schematic diagram of the connection between the initial preparation equipment, the ultrafiltration equipment and the centrifuge separation equipment and the gateway in one embodiment of the utility model.

[0039] Figure 4 This is a schematic diagram of the connection between the sterilization device and the gateway in one embodiment of the utility model.

[0040] Figure 5 This is a connection diagram between a redeployment device and a gateway in one embodiment of the utility model.

[0041] Figure 6 This is a schematic diagram of the connection between a filling device and a gateway in one embodiment of the utility model.

[0042] Figure 7This is a schematic diagram of the connection between an electric meter, a water meter, a gas meter, a temperature and humidity sensor and a gateway in one embodiment of the utility model. DETAILED DESCRIPTION

[0043] It should be noted that the following detailed descriptions are exemplary and are intended to provide further description of the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present invention belongs.

[0044] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention.

[0045] In the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0046] The utility model discloses a data collection and remote monitoring system for a juice production line; Figure 1 As shown, it includes: equipment layer, perception layer, transmission layer and management layer. The equipment layer includes a variety of production equipment, each of which is used to generate corresponding production data. The perception layer includes a variety of detection devices, which are connected to the corresponding production equipment to obtain the corresponding production data and upload it to the transmission layer. The transmission layer also communicates with the equipment layer and the management layer respectively.

[0047] The equipment layer includes cleaning equipment, pulping equipment, juicing equipment, primary mixing equipment, sterilization equipment, ultrafiltration equipment, centrifuge separation equipment, re-mixing equipment and filling equipment, etc. In some embodiments, the equipment layer also includes water meters, electricity meters and gas meters.

[0048] The perception layer includes a variety of detection devices for detecting corresponding production data, including flow sensors, temperature sensors, liquid level sensors, conductivity sensors, and temperature and humidity sensors. All of the above sensors are connected to their corresponding sensor instruments to display the detected data on site.

[0049] The transport layer includes PLC gateway, serial port server and DTU, etc.

[0050] The management installs the data collection platform, which refers to the server with data collection software installed.

[0051] Corresponding types of sensors are installed on the cleaning equipment, pulping equipment, juicing equipment, primary mixing equipment, ultrafiltration equipment, and centrifuge separation equipment, and each sensor is connected to the PLC gateway in the distribution box to upload the production data detected by the sensor to the data acquisition platform.

[0052] In a specific implementation, the cleaning device is used to clean fruits, and a flow sensor is installed in the buffer tank of the cleaning device. Specifically, the flow sensor is installed at the outlet of the pipeline at the bottom of the buffer tank to obtain the water flow of the cleaning device.

[0053] The pulping equipment is used to break the fruit into pulp to obtain pulp. A real-time temperature display instrument is installed on the pulping equipment. The real-time temperature display instrument consists of a temperature sensor PT100 and a digital display. In a specific implementation, three temperature sensors can be evenly installed from top to bottom in the inner tank of the pulping equipment to obtain the temperature of the inner tank of the pulping equipment to avoid high temperature affecting the quality of the pulp.

[0054] The juice extraction equipment fully squeezes the juice in the fruit to obtain juice. A flow sensor is installed at the bottom outlet of the juice extraction equipment to detect the flow of semi-finished fruit juice. The juice output of the juice extraction equipment can be obtained based on the data.

[0055] like Figure 2 As shown, the cleaning equipment, pulping equipment and juice extraction equipment are taken as a group, and the sensors of the three equipment are respectively connected to the PLC gateway in the first distribution box through cables, and the corresponding production data of the cleaning equipment, pulping equipment and juice extraction equipment are transmitted to the data acquisition platform through the PLC gateway.

[0056] The primary blending equipment mixes juice with other ingredients (such as sugar, acid, preservatives, etc.) in a certain proportion to obtain semi-finished fruit juice, so as to achieve the required taste and shelf life of the semi-finished fruit juice. Temperature sensors, liquid level sensors and conductivity sensors are installed on the primary blending equipment to obtain the production data of the primary blending equipment. Specifically, two temperature sensors are installed on each blending tank, one on the top and one on the bottom of the blending tank, which are perforated and sealed to obtain the temperature of the blending tank to prevent high temperature from affecting the quality of the semi-finished fruit juice; each blending tank is installed with a liquid level sensor to detect the amount of semi-finished fruit juice, which is installed at the lower water outlet of the blending tank; each blending tank is also installed with a conductivity sensor, which is installed at an appropriate position of the blending tank to detect conductivity and monitor the quality of the semi-finished fruit juice.

[0057] Ultrafiltration equipment is used to remove solid particles and impurities, such as pulp and peel fragments, from semi-finished fruit juice to obtain clear and transparent juice. Temperature sensors and liquid level sensors are installed on the ultrafiltration equipment. The temperature sensor is installed at the water outlet of the ultrafiltration equipment tank to obtain the temperature of the ultrafiltration equipment tank. The liquid level sensor is installed at the bottom of the tank to obtain the liquid level data of the ultrafiltration equipment. The flow sensor replaces the original float flow sensor position of the ultrafiltration equipment to obtain the flow data of the filtered juice.

[0058] Centrifuge separation equipment is used to separate solid particles of different densities or particle sizes from liquids, or to separate two immiscible liquids to obtain clarified juice. A flow sensor is installed on the centrifuge separation equipment. The flow sensor is installed at the outlet pipe of the centrifuge tank of the centrifuge separation equipment to obtain clarified juice flow data.

[0059] like Figure 3 As shown, the initial mixing equipment, ultrafiltration equipment and centrifuge separation equipment are taken as a group, and the sensors of the three equipment are respectively connected to the PLC gateway in the second distribution box through cables. The corresponding production data of the initial mixing equipment, ultrafiltration equipment and centrifuge separation equipment are transmitted to the data acquisition platform through the PLC gateway.

[0060] PLC gateways are added to the sterilization equipment, re-mixing equipment, and filling equipment to upload the corresponding production data to the data collection platform.

[0061] In a specific embodiment, the sterilization device is used to kill microorganisms in semi-finished fruit juice. Figure 4 As shown, a PLC gateway is installed in the control box of the sterilization equipment to transmit the production data of the sterilization equipment to the data acquisition platform. The production data of the sterilization equipment includes the first-effect cycle starting liquid level, the first-effect cycle starting liquid level, the three-effect cycle time, the second-effect cycle time, the condensate outlet starting time, the condensate pump starting time, the discharge density, the recovery density, the circulation density, the jam discharge density, the jam recovery density, the jam circulation starting liquid level, the jam circulation density, the jam screw pump starting liquid level, the jam inlet steam pressure, the cleaning downtime, the screw pump starting liquid level, the feed liquid level and the inlet steam pressure data, etc.

[0062] The re-blending equipment is used to perform the final seasoning and mixing before the juice is filled to obtain the finished juice, ensuring the flavor consistency of the juice and satisfying the taste needs of consumers. Figure 5 As shown, a PLC gateway is installed in the control box of the redistribution equipment to transmit the production data of the redistribution equipment to the data acquisition platform. The production data of the sterilization equipment includes the weight of the finished juice, liquid level data, etc.

[0063] Filling equipment is used to fill finished fruit juice, such as Figure 6 As shown, a PLC gateway is installed in the control cabinet of the filling equipment to transmit the production data of the filling equipment to the data acquisition platform. The production data of the filling equipment includes filling speed, cooling temperature, filling capacity, operating status, etc.

[0064] In a specific embodiment, data collection is also performed on electric meters, gas meters and water meters, such as Figure 7As shown, in the third distribution box, the electricity meter, gas meter and water meter are respectively connected to the PLC gateway to obtain real-time electricity consumption, gas consumption and water consumption and transmit them to the data acquisition platform. A temperature and humidity sensor can also be installed in the third distribution box to obtain environmental data in the distribution box to improve safety.

[0065] In a specific embodiment, the temperature and humidity in the workshop are also monitored. Three temperature and humidity collection points can be evenly set on the production line. For example, temperature and humidity sensors are set on the surface of the cleaning equipment, the surface of the ultrafiltration equipment, and the surface of the sterilization equipment to collect the temperature and humidity data in the workshop in real time, and transmit it to the data acquisition platform through the PLC gateway. The type, quantity, and location of the temperature and humidity sensors can be set according to actual needs, and there are no excessive restrictions here.

[0066] In a specific embodiment, a temperature and humidity sensor can also be installed in the distribution box to monitor the temperature and humidity data in the distribution box in real time, grasp the changes in temperature and humidity in the distribution box, and improve the safety of the distribution box. The temperature and humidity data are transmitted to the data acquisition platform through the PLC gateway, and the data is collected and stored in real time. It should be noted that technical personnel in this field can selectively install temperature and humidity sensors on the distribution box according to actual needs, and no excessive restrictions are made here.

[0067] In a specific embodiment, the PLC gateway can use PLCNET310, which is an industrial-grade full-featured PLC cloud gateway, mainly used to help PLC network, realize remote monitoring and data transmission of PLC, including remote debugging and program download. In this embodiment, PLCNET310 is used to collect PLC data, collect real-time data and store it. The PLC gateway uploads the real-time production data and historical production data of the entire production process to the data acquisition platform through the 4G network.

[0068] When the PLC gateway is set in the control cabinet of the sterilization equipment, re-dispensing equipment and filling equipment, each control cabinet is also equipped with switches, switching power supplies and air switches. The data collected by the PLC gateway in the equipment control cabinet is remotely transmitted to the data acquisition platform, and the monitoring data is collected and stored in real time. Add sensors and gateways to the data acquisition platform, configure variable templates and related rules, and perform real-time data collection and monitoring. Realize data collection and remote monitoring of the entire process of juice production.

[0069] The data collection platform uses the BS architecture to realize the real-time operation status of remote monitoring equipment, and realize real-time data monitoring, data collection and storage, summary statistics, historical data query, daily water consumption statistics, daily electricity consumption statistics, daily heat energy statistics, threshold alarm push and recording, etc. The data collection platform is used as a carrier for data storage and data display. All sensors communicate with the collection platform through the 4G network. When the data is collected to the platform, the corresponding alarm threshold is set, and when the data exceeds the threshold, relevant reminders are sent via SMS and email.

[0070] In a specific implementation, the flow sensor can adopt a DN38 flow sensor to collect flow data in real time and accumulate flow. To ensure the accuracy of the flow sensor measurement data, according to the flow sensor installation requirements, the minimum distance of the front 10DN (10 times the nominal diameter of the pipe) and the rear 5DN (5 times the nominal diameter of the pipe) must be met, DN nominal diameter (NominalDiameter, referred to as DN).

[0071] The temperature sensor can use a PT100 digital display to collect temperature data in real time and realize real-time online temperature measurement. It uses RS-485 transmission to transmit temperature and humidity data to the data acquisition platform of the management level through the PLC gateway to realize online temperature monitoring, data storage and historical data query.

[0072] Working principle of this utility model:

[0073] The utility model collects and networks the production data of equipment in all links of the juice production process, including cleaning, pulping, juicing, initial preparation, sterilization, ultrafiltration, centrifuge separation, re-preparation, and filling, to achieve remote monitoring of the real-time operating status of equipment in each production link, and to achieve real-time data monitoring, collection and storage, summary statistics, historical data query, daily water consumption statistics, daily electricity consumption statistics, daily thermal energy statistics, threshold alarm push and recording, etc. The data collection platform serves as a carrier for data storage and data display, and all sensors communicate with the collection platform through the 4G network. When the data is collected to the platform, the corresponding alarm threshold is set, and when the data exceeds the threshold, relevant reminders are sent via SMS and email.

[0074] Although the above describes the specific implementation methods of the utility model in combination with the accompanying drawings, it is not intended to limit the scope of protection of the utility model. Technical personnel in the relevant field should understand that on the basis of the technical solution of the utility model, various modifications or deformations that can be made by technical personnel in this field without creative work are still within the scope of protection of the utility model.

Claims

1. A data collection and remote monitoring system for a juice production line, characterized in that: Includes device layer, perception layer, transmission layer and management layer; The equipment layer includes a plurality of production equipment, each of which is used to generate corresponding production data; The perception layer includes a variety of detection devices for acquiring the corresponding production data and uploading it to the transmission layer; The transport layer also communicates with the device layer and the management layer respectively.

2. A data collection and remote monitoring system for a juice production line as claimed in claim 1, characterized in that: The management layer installs a data collection platform, and the data collection platform refers to a server on which data collection system software is installed.

3. The data collection and remote monitoring system for a juice production line according to claim 1, characterized in that: The transport layer includes a gateway, a serial port server and a DTU.

4. The data collection and remote monitoring system for a juice production line according to claim 1, characterized in that: The equipment layer includes cleaning equipment, pulping equipment, juicing equipment, primary mixing equipment, sterilization equipment, ultrafiltration equipment, centrifuge separation equipment, re-mixing equipment and filling equipment.

5. A data collection and remote monitoring system for a juice production line as claimed in claim 4, characterized in that: Corresponding types of sensors are installed on the cleaning equipment, pulping equipment, juicing equipment, primary mixing equipment, ultrafiltration equipment, and centrifuge separation equipment, and each sensor is connected to the transmission layer to upload the production data detected by the sensor to the management layer.

6. A data collection and remote monitoring system for a juice production line as claimed in claim 5, characterized in that: The cleaning equipment is equipped with a flow sensor; The beating equipment is equipped with a temperature sensor; The juice extraction device is equipped with a flow sensor; The initial mixing equipment is equipped with a temperature sensor, a liquid level sensor and a conductivity sensor; The ultrafiltration equipment is equipped with a temperature sensor and a liquid level sensor; The centrifuge separation device is equipped with a flow sensor.

7. The data collection and remote monitoring system for a juice production line according to claim 4, characterized in that: The sterilization equipment, re-blending equipment, and filling equipment are respectively connected to the transmission layer to upload the corresponding production data to the management layer.

8. The data collection and remote monitoring system for a juice production line according to claim 1, characterized in that: The perception layer also includes a plurality of temperature and humidity sensors distributed in the workshop, which are used to collect temperature and humidity data, and transmit the temperature and humidity data to the management layer through the transmission layer.

9. The data collection and remote monitoring system for a juice production line according to claim 1, characterized in that: The equipment layer also includes electricity meters, gas meters and water meters.

10. A data collection and remote monitoring system for a juice production line as claimed in claim 9, characterized in that: The electric meter, gas meter and water meter transmit the real-time electricity consumption, gas consumption and water consumption data to the management layer through the transmission layer respectively.

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