Dust, oil mist and corrosive gas self-detection system of measurement and control equipment
Through the integration of dust, oil mist and corrosive gas detection modules and data processing, the problem that existing equipment cannot monitor multiple pollutants at the same time is solved, efficient and accurate industrial environment monitoring is achieved, and the system adaptability and stability is improved.
Patent Information
- Application Number
- CN202422407118.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-30
- Publication Date
- 2025-08-26
- Estimated Expiration
- 2034-09-30
AI Technical Summary
Existing industrial environmental testing equipment cannot detect dust, oil mist and corrosive gases simultaneously, resulting in equipment failure and production stagnation.
A self-detection system for measuring and controlling equipment is designed, integrating dust, oil mist and corrosive gas detection modules. Data is collected through photoelectric sensors and electrochemical sensors, and data processing and threshold model training are combined with random forest models to achieve comprehensive monitoring and automatic adjustment of various pollutants.
It improves the coverage and data accuracy of industrial environment monitoring, reduces false alarms and missed reports, enhances the adaptability and stability of the system, reduces labor intensity, and improves monitoring efficiency.
Smart Images
Figure CN223272507U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the technical field of industrial environment detection equipment, and more specifically, to a measurement and control equipment self-detection system for dust, oil mist, and corrosive gas. Background Art
[0002] With the continuous development of industrial automation, automatic control modules are increasingly used in various industrial control systems, especially those equipped with PLCs (Programmable Logic Controllers). However, industrial environments are often accompanied by pollutants such as dust, oil mist, and corrosive gases. These pollutants can seriously affect the normal operation of control modules, leading to equipment failures and production stagnation.
[0003] Currently, there is a technology and system on the market for industrial environment monitoring that can monitor harmful gases in the environment in real time. However, this system mainly focuses on the detection of a single gas and cannot simultaneously monitor other pollutants such as dust and oil mist.
[0004] There is also an environmental monitoring system on the market that uses multiple sensors to monitor environmental parameters such as temperature, humidity, and dust concentration. However, this system lacks the ability to detect oil mist and corrosive gases.
[0005] Therefore, developing a measurement and control equipment system that can self-detect dust, oil mist and corrosive gas has important practical significance and market demand. Utility Model Content
[0006] The purpose of this application is to propose a self-detection system for dust, oil mist and corrosive gas of measurement and control equipment to solve the technical problem that existing industrial environment detection equipment cannot detect dust, oil mist and corrosive gas at the same time.
[0007] To achieve the above-mentioned purpose, the technical solution adopted in this application is: to provide a system for self-detection of dust, oil mist and corrosive gas in measurement and control equipment, including a detection module, a control module and a data processing module;
[0008] The detection module includes a dust detection module, an oil mist detection module and a gas detection module, which are used to collect dust concentration, oil mist concentration and corrosive gas concentration in the environment and convert the physical quantities into first detection data;
[0009] The control module includes a main controller and a data transmission interface, the main controller is connected to the detection module via the data transmission interface, and the data transmission interface is used to complete data exchange between the main controller and the detection module;
[0010] The data processing module is connected to the main controller and is used to perform model training on the first detection data and generate a threshold model. The main controller is used to compare the first detection data with the threshold model and determine the warning.
[0011] Furthermore, the dust detection module includes a photoelectric dust sensor provided with a light source, the photoelectric dust sensor is connected to the main controller via the data transmission interface, and the photoelectric dust sensor detects dust concentration by detecting the light intensity when light passes through dust particles.
[0012] Furthermore, the oil mist detection module includes a light source and a photodetector. The photodetector is connected to the main controller via the data transmission interface. The photodetector detects the oil mist concentration by detecting the light intensity when the light passes through the oil mist particles.
[0013] In some embodiments, the gas detection module includes an electrochemical sensor, which is connected to the main controller via the data transmission interface. The electrochemical sensor is provided with an electrode for reacting with corrosive gas.
[0014] Furthermore, the data transmission interface includes an SPI interface, the main controller is the master device of the SPI interface, used to control the timing of communication and data exchange, and the detection module is the slave device of the SPI interface, used to receive commands from the main controller and return data.
[0015] In some embodiments, the control module also includes an analog-to-digital converter connected to the data transmission interface, the first detection data is an analog signal, and the analog-to-digital converter is connected to the dust detection module, the oil mist detection module and the gas detection module, and is used to perform analog-to-digital conversion on the data exchanged between the main controller and the detection module.
[0016] Furthermore, the control module further comprises a real-time clock module connected to the main controller, and the real-time clock module is used to trigger data exchange between the main controller and the detection module on a regular or periodic basis.
[0017] In some embodiments, the main controller is further connected to an external crystal oscillator, and the external crystal oscillator is connected to an external battery.
[0018] Furthermore, the data processing module includes a host computer system, and a random forest model is integrated into the host computer system. The first detection data is comprehensively evaluated after training with the random forest model to achieve accurate discrimination of components and contents in the object being measured.
[0019] In some embodiments, the threshold model is stored on the master controller.
[0020] The beneficial effects of the self-detection system for dust, oil mist, and corrosive gases provided by this application are at least as follows: the system of this embodiment integrates dust detection modules, oil mist detection modules, and gas detection modules. This multi-detection module fusion technology enables the system to comprehensively monitor multiple pollutants in industrial environments, surpassing the existing technology's ability to monitor only a single or limited number of pollutants. By integrating multiple detection modules, the system not only improves monitoring coverage but also enhances data accuracy and reliability, as multiple data sources can verify each other, reducing the possibility of false positives and missed positives.
[0021] The data processing module uses model training to enable the system to automatically adjust detection parameters based on real-time environmental changes. This not only improves detection accuracy but also enhances the system's adaptability, enabling it to operate stably in various industrial environments. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the embodiments or descriptions of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.
[0023] Figure 1 This is a module block diagram of the self-detection system for dust, oil mist, and corrosive gases of the measurement and control equipment provided in an embodiment of the present application.
[0024] Among them, the reference numerals in the figures are:
[0025] 1. Detection module; 11. Dust detection module; 12. Oil mist detection module; 13. Gas detection module;
[0026] 2. Control module; 21. Main controller; 22. Data transmission interface; 23. Analog-to-digital converter; 24. Real-time clock module;
[0027] 3. Data processing module. DETAILED DESCRIPTION
[0028] In order to make the technical problems, technical solutions and beneficial effects to be solved by this application more clearly understood, the present application is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this application and are not intended to limit this application.
[0029] It should be noted that when a component is referred to as being "fixed on" or "disposed on" another component, it may be located directly or indirectly on the other component. When a component is referred to as being "connected to" another component, it may be directly or indirectly connected to the other component. The directions or positions indicated by the terms "upper", "lower", "left", "right", "front", "back", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc. are based on the directions or positions shown in the accompanying drawings and are only for the convenience of description and cannot be understood as limitations on this technical solution. The terms "first" and "second" are only used for the purpose of convenience of description and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features. "Multiple" means two or more, unless otherwise clearly and specifically defined.
[0030] The following describes the self-detection system of dust, oil mist, and corrosive gas of the measurement and control equipment in an embodiment of the present application in conjunction with the accompanying drawings.
[0031] See also Figure 1 , Figure 1 The module block diagram of the self-detection system of dust, oil mist and corrosive gas of the measurement and control equipment of the present application is shown, including a detection module 1, a control module 2 and a data processing module 3.
[0032] The detection module 1 includes a dust detection module 11 , an oil mist detection module 12 and a gas detection module 13 , and is used to collect dust concentration, oil mist concentration and corrosive gas concentration in the environment and convert the physical quantities into first detection data.
[0033] The control module 2 includes a main controller 21 and a data transmission interface 22 . The main controller 21 is connected to the detection module 1 via the data transmission interface 22 . The data transmission interface 22 is used to complete data exchange between the main controller 21 and the detection module 1 .
[0034] The data processing module 3 is connected to the main controller 21 and is used to perform model training on the first detection data and generate a threshold model. The main controller 21 is used to compare the first detection data with the threshold model and determine the warning.
[0035] During detection, the main controller 21 of the control module 2 initializes and configures the dust detection module 11, the oil mist detection module 12 and the gas detection module 13 through the data transmission interface 22, and each detection module 1 begins to collect data on the dust concentration, oil mist concentration and corrosive gas concentration in the environment.
[0036] Then, the dust, oil mist and corrosive gas data in the environment of the detection module 1 are converted into analog signals (such as 4-20mA or 0-10V). The main controller 21 of the control module 2 reads these signals and performs preliminary processing on the data signal of the mobile phone (such as normalization and scaling).
[0037] Next, the main controller 21 inputs the preliminarily processed data into the data processing module 3 , which uses historical data and real-time data to train and generate a threshold model, evaluate the data from the detection module 1 , and predict the presence and concentration of pollutants.
[0038] Finally, the main controller 21 performs system adjustments or alarms based on the predictions of the threshold model. If the pollutant concentration exceeds the concentration threshold in the threshold model, the control module 2 triggers an alarm or corrective action.
[0039] The system in this embodiment integrates a dust detection module 11, an oil mist detection module 12, and a gas detection module 13. This fusion of multiple detection modules 1 enables the system to comprehensively monitor multiple pollutants in industrial environments, surpassing the capabilities of existing technologies that can only monitor a single or limited number of pollutants. By integrating multiple detection modules 1, the system not only improves monitoring coverage but also enhances data accuracy and reliability. This is because multiple data sources can verify each other, reducing the possibility of false positives and missed positives.
[0040] Furthermore, data processing module 3 uses model training to enable the system to automatically adjust detection parameters based on real-time environmental changes. This not only improves detection accuracy but also enhances the system's adaptability, enabling stable operation in a variety of industrial environments. For example, if a sudden increase in oil mist or dust concentration is detected, the system can instantly adjust the sensitivity of detection module 1 or modify the data collection frequency to ensure data quality and timely system response.
[0041] Compared with traditional manual monitoring methods, the automated system significantly reduces labor intensity and improves monitoring efficiency. It reduces dependence on professionals, simplifies operational processes, and enables companies to deploy human resources more effectively.
[0042] Furthermore, the control module 2 includes a PLC module, and automatic control is achieved through the PLC module.
[0043] Of course, the control module 2 can also be the main control unit in a distributed control system (DCS), which is used to receive data, execute control algorithms, and send control commands back to field equipment (dust detection module 11, oil mist detection module 12 and gas detection module 13), and can provide more powerful processing capabilities, richer software tools and better human-machine interface than the PLC module.
[0044] In some embodiments, the dust detection module 11 includes a photoelectric dust sensor provided with a light source. The photoelectric dust sensor is connected to the main controller 21 via a data transmission interface 22. The photoelectric dust sensor detects dust concentration by detecting the light intensity when light passes through dust particles.
[0045] Furthermore, the light source of the photoelectric dust sensor emits light. When the light passes through the air, if there are dust particles in the air, these particles will scatter or absorb part of the light. The light that is not absorbed or scattered by the dust will shine on the photosensitive element. The more dust there is, the less light will reach the photosensitive element.
[0046] The photoelectric dust sensor's photosensor generates an electrical signal based on changes in received light intensity. Strong light intensity results in a higher current flow, while weak light intensity results in a lower current flow. Thus, changes in light intensity are converted into changes in an electrical signal. The photoelectric dust sensor transmits the collected analog electrical signal to the main controller 21 via the data transmission interface 22.
[0047] The photoelectric dust sensor includes any one of a scattering photoelectric sensor, a transmission photoelectric sensor, and a laser particle counter, or a combination thereof.
[0048] In some embodiments, the oil mist detection module 12 includes a light source and a photodetector. The photodetector is connected to the main controller 21 via a data transmission interface 22. The photodetector detects the oil mist concentration by detecting the intensity of light passing through the oil mist particles.
[0049] The oil mist detection module 12 is equipped with a light source and a photodetector. When oil mist particles pass through the photodetector, the light transmission path or capacitance value will be changed, so that the photodetector can detect the change in oil mist concentration. The change in light intensity is converted into a change in electrical signal.
[0050] Furthermore, the photoelectric detector includes any one of a static laser scatterer, a dynamic laser scatterer, and a laser diffractometer, or a combination thereof.
[0051] Furthermore, the oil mist detection module 12 further includes a chemical detection module 1. Exemplarily, the chemical detection module 1 includes a gas chromatograph-mass spectrometer for separating and identifying compounds in a complex mixture.
[0052] In some embodiments, the gas detection module 13 includes an electrochemical sensor, which is connected to the main controller 21 via a data transmission interface 22 . The electrochemical sensor is provided with electrodes for reacting with corrosive gases.
[0053] Electrochemical sensors use chemical reactions between gases and electrodes to produce current changes. The gas molecules to be measured are adsorbed onto the electrode surface of the sensor, where they undergo redox reactions. The electrochemical reactions produce changes in current or potential. The changes in current or potential are converted into electrical signals through circuits. The electrical signals are converted into digital signals and analyzed by a data processing unit to ultimately display the concentration of the gas.
[0054] In some embodiments, the data transmission interface 22 includes an SPI interface (Serial Peripheral Interface, synchronous serial interface), the main controller 21 is the master device of the SPI interface, used to control the timing and data exchange of communication, and the detection module 1 is the slave device of the SPI interface, used to receive commands from the main controller 21 and return data.
[0055] The SPI communication between the detection module 1 and the main controller 21 can be achieved by the following steps:
[0056] Hardware Connection:
[0057] The main controller 21 acts as the master device of SPI, controlling the communication timing and data exchange, and the detection module 1 acts as the slave device of SPI, receiving commands from the main controller 21 and returning data.
[0058] Connections: These typically include four lines: the serial clock line (SCLK), the master output slave input (MOSI), the master input slave output (MISO), and the chip select line (CS). These connections ensure accurate and synchronous data transmission between the main controller 21 and the detection module 1.
[0059] Data transmission protocol:
[0060] First, initialization is performed, and the main controller 21 configures the communication parameters of the SPI, such as clock frequency, data transmission bits and communication mode.
[0061] Chip select activation: Before communication begins, the main controller 21 activates a specific detection module 1 through the chip select line (CS).
[0062] Send command: The main controller 21 sends a read instruction to the detection module 1 through the MOSI line.
[0063] Data reception: The detection module 1 responds to the instruction and sends the data back to the main controller 21 through the MISO line.
[0064] End of communication: After data transmission is completed, the main controller 21 closes the communication with the detection module 1 through the chip select line (CS).
[0065] Software Control:
[0066] Driver: The main controller 21 needs to write a corresponding SPI communication driver to manage the sending and receiving of data.
[0067] Data processing: The received sensor data needs to be processed and analyzed in the main controller 21 and will also be used for further decision support or anomaly detection.
[0068] Error handling and synchronization:
[0069] Error detection: The main controller 21 needs to be able to detect and handle errors that may occur in SPI communication, such as data collisions or synchronization problems.
[0070] Timing control: Accurate timing control is the key to ensure stable data transmission. The main controller 21 ensures correct reading and writing of data by controlling the clock line (SCLK).
[0071] In some embodiments, the control module 2 further includes an analog-to-digital converter (ADC) 23 connected to the data transmission interface 22. The ADC 23 is connected to the dust detection module 11, the oil mist detection module 12, and the gas detection module 13, and is configured to perform analog-to-digital conversion on the data exchanged between the main controller 21 and the detection module 1. The first detection data is an analog signal, which is converted into a digital signal by the ADC module.
[0072] Furthermore, the control module 2 also includes a real-time clock module 24 (RTC module) connected to the main controller 21. The real-time clock module 24 is used to regularly or periodically trigger data exchange between the main controller 21 and the detection module 1. The operating status of the detection module 1 and the control module 2 is regularly checked to ensure the stability and reliability of the system.
[0073] Furthermore, the main controller 21 is also connected to an external crystal oscillator, which is connected to an external battery. The external crystal oscillator is used to provide an accurate time reference. The oscillator inside the real-time clock module 24 can use the external crystal oscillator to generate a stable clock signal, thereby ensuring the accuracy of time.
[0074] In some embodiments, the data processing module 3 includes a host computer system, which has a random forest model integrated inside. The first detection data is comprehensively evaluated after being trained with the random forest model to achieve accurate identification of the components and contents in the object being measured.
[0075] Furthermore, the threshold model is stored on the main controller 21, and the trained threshold model is deployed on the main controller 21 of the control module 2 for triggering scheduled tasks or periodic events to realize online prediction and anomaly detection of real-time data of the detection module 1.
[0076] The above are only preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements, and improvements made within the spirit and principles of the present application should be included in the scope of protection of the present application.
Claims
1. A measurement and control equipment self-detection system for dust, oil mist, and corrosive gas, characterized in that: It includes a detection module, a control module and a data processing module; The detection module includes a dust detection module, an oil mist detection module and a gas detection module, which are used to collect dust concentration, oil mist concentration and corrosive gas concentration in the environment and convert the physical quantities into first detection data; The control module includes a main controller and a data transmission interface, the main controller is connected to the detection module via the data transmission interface, and the data transmission interface is used to complete data exchange between the main controller and the detection module; The data processing module is connected to the main controller and is used to perform model training on the first detection data and generate a threshold model. The main controller is used to compare the first detection data with the threshold model and determine the warning.
2. The self-detection system for dust, oil mist and corrosive gas of measurement and control equipment according to claim 1 is characterized in that: The dust detection module includes a photoelectric dust sensor provided with a light source. The photoelectric dust sensor is connected to the main controller via the data transmission interface. The photoelectric dust sensor detects dust concentration by detecting the light intensity when light passes through dust particles.
3. The self-detection system for dust, oil mist and corrosive gas of measurement and control equipment according to claim 1 is characterized in that: The oil mist detection module includes a light source and a photoelectric detector. The photoelectric detector is connected to the main controller via the data transmission interface. The photoelectric detector detects the oil mist concentration by detecting the light intensity when the light passes through the oil mist particles.
4. The self-detection system for dust, oil mist and corrosive gas of measurement and control equipment according to claim 1 is characterized in that: The gas detection module includes an electrochemical sensor, which is connected to the main controller via the data transmission interface. The electrochemical sensor is provided with an electrode for reacting with corrosive gas.
5. The self-detection system for dust, oil mist and corrosive gas of measurement and control equipment according to any one of claims 1 to 4, characterized in that: The data transmission interface includes an SPI interface, the main controller is the master device of the SPI interface, and is used to control the timing of communication and data exchange. The detection module is the slave device of the SPI interface, and is used to receive commands from the main controller and return data.
6. The self-detection system for dust, oil mist and corrosive gas of the measurement and control equipment according to claim 5 is characterized in that: The control module also includes an analog-to-digital converter connected to the data transmission interface. The first detection data is an analog signal. The analog-to-digital converter is connected to the dust detection module, the oil mist detection module and the gas detection module, and is used to perform analog-to-digital conversion on the data exchanged between the main controller and the detection module.
7. The self-detection system for dust, oil mist and corrosive gas of measurement and control equipment according to claim 5 is characterized in that: The control module further comprises a real-time clock module connected to the main controller, and the real-time clock module is used for timing or periodically triggering data exchange between the main controller and the detection module.
8. The self-detection system for dust, oil mist and corrosive gas of measurement and control equipment according to claim 7 is characterized in that: The main controller is further connected to an external crystal oscillator, and the external crystal oscillator is connected to an external battery.
9. The self-detection system for dust, oil mist and corrosive gas of measurement and control equipment according to claim 5, characterized in that: The data processing module includes a host computer system, and a random forest model is integrated into the host computer system. The first detection data is comprehensively evaluated after being trained with the random forest model to achieve accurate discrimination of the components and contents in the object being measured.
10. The self-detection system for dust, oil mist and corrosive gas of measurement and control equipment according to claim 5, characterized in that: The threshold model is stored on the master controller.