Device monitoring system

Abstract

This application relates to the field of Internet of Things (IoT) technology and provides a device monitoring system. The system includes: a detection and execution layer for collecting first operational data corresponding to a target device, wherein the target device includes equipment related to irrigation device production, and different target devices correspond to different network segments; a logic control layer connected to the detection and execution layer for acquiring the first operational data collected by the detection and execution layer; a network conversion layer connected to the logic control layer for converting the first operational data into second operational data under a unified network segment; a switch layer for connecting the second operational data to a process monitoring layer; and a process monitoring layer for monitoring the target device based on the second operational data and issuing an alarm when an anomaly is detected. This application improves the efficiency and reliability of device monitoring.

Description

Technical Field

[0001] This application relates to the field of Internet of Things (IoT) technology, and more particularly to a device monitoring system. Background Technology

[0002] The production equipment in an irrigation device factory is diverse, mainly divided into two categories: key production equipment, including double-cone drying systems and pulsed vacuum drying cabinets, and production support equipment, including chillers, air conditioning systems for each workshop, and water purification systems. Abnormal parameters of the production equipment during operation can affect the quality of the irrigation devices produced; therefore, it is essential to monitor the operating parameters of the production equipment during the production process.

[0003] Currently, the operating parameters of production equipment are typically recorded manually by relevant monitoring personnel at regular intervals. These personnel rely on their personal experience to monitor for parameter anomalies and notify relevant personnel to handle any abnormalities. This method is not only inefficient but also prone to errors due to its reliance on human experience. Utility Model Content

[0004] This application provides an equipment monitoring system designed to improve the efficiency and reliability of equipment monitoring.

[0005] To achieve the above objectives, this application provides an equipment monitoring system, the equipment monitoring system comprising:

[0006] The detection execution layer is used to collect the first operating data corresponding to the target device, wherein the target device includes equipment related to the production of the irrigation device, and different target devices correspond to different network segments;

[0007] A logic control layer, which is connected to the detection and execution layer, is used to acquire the first running data collected by the detection and execution layer;

[0008] A network conversion layer, which is connected to the logic control layer, is used to convert the first running data into second running data under a unified network segment;

[0009] A switch layer, which is used to connect the second operating data to the process monitoring layer;

[0010] The process monitoring layer is used to monitor the target device based on the second operating data and to issue an alarm when an anomaly is detected.

[0011] In the equipment monitoring system of one embodiment of this application, the logic control layer includes at least one of a PLC controller and a frequency converter, the switch layer includes a floor switch, and the PLC controller or the frequency converter is connected to the floor switch.

[0012] In the equipment monitoring system of one embodiment of this application, when the PLC controller body includes a serial port, a serial port / network port conversion module is configured to expand the corresponding network port and then connect to the floor switch.

[0013] In the equipment monitoring system of one embodiment of this application, when the PLC controller body includes a network port and the corresponding IP address is not in the same network segment as the industrial control network IP address, the IP address of the network port is mapped to the industrial control network IP address based on the network coupler and then connected to the floor switch.

[0014] In the equipment monitoring system of one embodiment of this application, when the PLC controller body includes a network port and forms a local area network with other devices through a local switch, a network coupler is connected to the local switch, and the IP address of the network port is mapped to an industrial control network IP address based on the network coupler before being connected to the floor switch.

[0015] In the equipment monitoring system of one embodiment of this application, the frequency converter supports a serial communication protocol and is connected to the floor switch after the serial communication protocol is converted into a TCP communication protocol.

[0016] In the equipment monitoring system of one embodiment of this application, the process monitoring layer includes a SCADA server and an OPC server. The SCADA server performs data monitoring and alarm based on the second operating data, and uploads relevant monitoring information to the cloud through the OPC server. The relevant monitoring information includes at least one of operating status information and alarm information.

[0017] In the equipment monitoring system according to one embodiment of this application, an Internet of Things (IoT) module is installed on one end of the SCADA server. The IoT module performs secondary alarm judgment. If it is determined that a secondary alarm is required, secondary alarm information is generated and uploaded to the cloud through the OPC server.

[0018] In the equipment monitoring system of one embodiment of this application, the target equipment includes multiple devices, and the process monitoring layer performs joint data monitoring and abnormal alarm judgment based on the second operating data corresponding to the multiple target devices.

[0019] In the device monitoring system of one embodiment of this application, the device monitoring system further includes a front-end display layer, which is used to display relevant monitoring information of the target device, including at least one of operating status information and alarm information.

[0020] This application discloses an equipment monitoring system, which includes a detection and execution layer for collecting first operating data corresponding to target equipment, wherein the target equipment includes equipment related to irrigation device production, and different target equipment corresponds to different network segments; a logic control layer connected to the detection and execution layer for acquiring the first operating data collected by the detection and execution layer; a network conversion layer connected to the logic control layer for converting the first operating data into second operating data under a unified network segment; a switch layer for connecting the second operating data to a process monitoring layer; and a process monitoring layer for monitoring the target equipment based on the second operating data and issuing alarms when abnormalities are detected. The monitoring process of the target equipment does not rely on manual experience operation, thus improving the efficiency and reliability of equipment monitoring. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of a device monitoring system provided in an embodiment of this application;

[0023] Figure 2 This is a schematic diagram of the architecture of a device monitoring system provided in an embodiment of this application;

[0024] Figure 3 This is a schematic diagram of another device monitoring system provided in an embodiment of this application;

[0025] Figure 4 This is a schematic diagram illustrating the display of relevant monitoring information provided in an embodiment of this application;

[0026] Figure 5 This is a schematic diagram illustrating another display of related monitoring information provided in an embodiment of this application;

[0027] Figure 6 This is a network topology diagram of a device monitoring system provided in an embodiment of this application. Detailed Implementation

[0028] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0029] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the order described. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0030] It should be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0031] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0032] The production equipment in perfusion device (such as hemoperfusion devices) factories is diverse, mainly divided into two categories: key production equipment, including double-cone drying systems and pulsed vacuum drying cabinets; and production support equipment, including chillers, air conditioning systems for each workshop, and water purification systems (including purified water, multi-effect distillation machines, and distribution systems). Abnormalities in various parameters of the production equipment during operation can lead to fluctuations in product quality; therefore, it is essential to monitor the operating parameters of the production equipment during the production process.

[0033] In traditional irrigation equipment production, operating parameters need to be recorded manually. Monitoring personnel (such as workshop operators) must manually transcribe these parameters at regular intervals. They rely on extensive experience to monitor these parameters and intervene if they deem abnormal. This requires constant on-site monitoring, resulting in high labor costs, low efficiency, and potentially erroneous judgments based on personal experience. Furthermore, current methods require monitoring personnel to inspect multiple workshops for anomalies, hindering timely detection and notification of relevant personnel. Additionally, the production status and operating parameters of upstream equipment can influence downstream equipment; however, current technology controls each device independently, preventing the joint assessment of anomalies based on multiple device parameters.

[0034] To address the aforementioned issues, embodiments of this application provide a device monitoring system for improving the efficiency and reliability of device monitoring.

[0035] Please see Figure 1 , Figure 1This is a schematic diagram of the structure of an equipment monitoring system provided in an embodiment of this application.

[0036] like Figure 1 As shown, the equipment monitoring system 1000 includes a detection execution layer 100, a logic control layer 200, a network conversion layer 300, a switch layer 400, and a process monitoring layer 500.

[0037] The detection execution layer 100 includes various types of sensors, such as... Figure 2 As shown, various sensors include pressure sensors, flow meters, temperature sensors, etc. The detection execution layer 100 collects operational data corresponding to the target equipment. For ease of description, the operational data collected by the detection execution layer 100 will be referred to as the first operational data below. Target equipment includes equipment related to perfusion device production, such as dual-cone drying systems, pulsed vacuum drying cabinets, chillers, air conditioning systems, water purification systems, etc., where different target devices correspond to different network segments. Of course, target equipment can also be other types of electronic equipment; this application does not specifically limit the type of target equipment.

[0038] The logic control layer 200 is connected to the detection and execution layer 100. The first operating parameters collected by the detection and execution layer 100 are transmitted to the logic control layer 200, and the logic control layer 200 acquires the first operating data collected by the detection and execution layer 100. For example, the logic control layer 200 includes at least one of a PLC (Programmable Logic Controller) controller and a frequency converter, such as... Figure 2 As shown, PLC controllers can include series such as S7-200, S7-300, S7-1200, S7-1500, and 200-SMART.

[0039] The network conversion layer 300 connects to the logic control layer 200, and converts the first operational data from the logic control layer 200 into second operational data output under a unified network segment. For example, the network conversion layer 300 includes a network coupler, such as... Figure 2 As shown, the network coupler connects to PLC controllers such as S7-200, S7-300, S7-1200, S7-1500, and 200-SMART.

[0040] Switching layer 400 connects network conversion layer 300 and process monitoring layer 500. Switching layer 400 transmits the second operating data converted by network conversion layer 300 to process monitoring layer 500. For example, switching layer 400 includes floor switches and aggregation switches. PLC controllers or frequency converters are connected to floor switches via network couplers. Floor switches transmit the second operating data to aggregation switches, then to industrial firewalls, and finally to process monitoring layer 500.

[0041] The process monitoring layer 500 monitors the target equipment based on the acquired second operational data and issues an alarm when an anomaly is detected. For example, the process monitoring layer 500 includes a database, an OPC (OLE for Process Control) server, a SCADA (Supervisory Control and Data Acquisition) server, and a MES (Manufacturing Execution System), etc. For instance, such as... Figure 2 As shown, after connecting to the industrial firewall, it interfaces with the SCADA server. The SCADA server communicates with the OPC server to read the second operational data, perform data monitoring and alarms, and upload relevant monitoring information to the cloud via the OPC server. This monitoring information includes at least one of operational status information and alarm information. Equipment operators, managers, and other users can monitor the operation of the target equipment and receive alarm information through the cloud. Additionally, the second operational data is stored in a database. The MES system reads this data from the database for production monitoring, such as production output monitoring and recording the time of changes in the target equipment's operational status.

[0042] In some embodiments, such as Figure 3 As shown, the device monitoring system 1000 also includes a front-end display layer 600, which displays relevant monitoring information of the target device. This relevant monitoring information includes at least one of operational status information and alarm information. For example, the front-end display layer 600 may include, but is not limited to, mobile apps, PCs, and large screens. Figure 2 As shown, the device interconnects with mobile apps, PCs, and large screens via communication protocols supported by the IoT (Internet of Things) gateway, including MQTT (Message Queuing Telemetry Transport), WebSocket (a full-duplex communication protocol based on TCP (Transmission Control Protocol)), and HTTP (Hypertext Transfer Protocol). After relevant monitoring information is uploaded to the cloud, equipment operators, managers, and other users can conveniently and promptly view operational status and alarm information through mobile apps, PCs, and large screens. For example, operational data and alarm information can be viewed through a mobile app, or alarm information can be pushed via WeChat, SMS, etc. The method of displaying information in this application is not specifically limited.

[0043] For example, suppose the target devices include device A, device B, and device C, and the task is to monitor device A, device B, and device C. Figure 4 As shown, the monitoring interface of the mobile app can display the operating data 'a' for device A, the operating data 'b' for device B, and the operating data 'c' for device C. For example, if device A is detected to be operating abnormally, such as... Figure 5 As shown, alarm messages such as "Device A is malfunctioning!!" can be displayed on the monitoring interface of the mobile APP.

[0044] In some embodiments, the PLC controllers used in early workshop control systems are discontinued, and their CPUs (Central Processing Units) are equipped with serial ports (e.g., RS485) but lack network ports (e.g., RJ45). Since the serial port is used for HMI (Human Machine Interface) communication, there is essentially no hardware communication capability. To address the situation where the PLC controller only has a serial port, a serial-to-network port conversion module is added. This module expands the network port, for example, to an RJ45 port, which can be configured with an IP address. This port is then connected to a floor switch, while the serial port continues to be used for HMI communication and local monitoring.

[0045] like Figure 6 As shown, using Figure 6 In the first communication method, the serial port PPI (Point-to-Point Interface) protocol is converted into the Ethernet communication TCP / IP (Internet Protocol) protocol through a serial port / Ethernet port conversion module, and then the host computer performs data acquisition through the TCP protocol.

[0046] In some embodiments, the PLC controller body includes a network port, such as an RJ45 network port, but the IP address is not in the same network segment as the industrial control network IP address. In this case, an IP address conversion is performed through a network coupler to map the original IP address (e.g., 192.168.xx) to the industrial control network IP address (e.g., 172.10.xx), and then it is connected to the floor switch. Another interface is directly mapped to the original 192.168.xx address to continue communicating with the local frequency converter, servo, HMI, etc.

[0047] like Figure 6 As shown, using Figure 6Communication method ② uses a network coupler to split the original network port IP address (e.g., 192.168.xx) into two interfaces. One interface continues to use the original IP address (e.g., 192.168.xx) network segment to communicate with frequency converters, servos, HMIs (e.g., local touch screens), etc. The other interface maps the original IP address network segment to the industrial control network IP address (e.g., 172.10.xx) network segment to realize the PLC controller's cross-network segment IP address translation. Then, the host computer performs data acquisition through protocols such as TCP and UDP (User Datagram Protocol).

[0048] In some embodiments, the PLC controller body includes a network port, such as an RJ45 network port, and forms a local area network with other devices through a local switch. In this case, a network coupler is connected to the local switch, and the IP address of the network port (e.g., 192.168.xx) is mapped to an industrial control network IP address (e.g., 172.10.xx) based on the network coupler before being connected to the floor switch.

[0049] like Figure 6 As shown, using Figure 6 In communication method ③, the Modbus RTU (Remote Terminal Unit) communication protocol is converted into the Modbus TCP protocol, and then the host computer performs data acquisition through the TCP / IP protocol.

[0050] In some embodiments, since the frequency converter only supports serial communication protocols, such as the Modbus RTU communication protocol, the serial communication protocol is converted to the TCP communication protocol before being connected to the floor switch. For example, the Modbus RTU is converted to Modbus TCP through an RTU conversion module before being connected to the floor switch.

[0051] like Figure 6 As shown, using Figure 6 Communication method ④: Through a serial port / network port conversion module, the communication protocol of the serial port (such as RS422 / 232 serial port) FX / Q programming port is converted into the Ethernet communication MC (MELSEC Communication) / Modbus TCP protocol, and then the host computer performs data acquisition through the TCP protocol.

[0052] After connecting all PLC controllers and frequency converters to the floor switch using the above method, they are then connected to the aggregation switch in each factory area, and finally connected to the industrial firewall to interface with the SCADA server.

[0053] For example, the host computer uses the Siemens WINCC platform, integrating Siemens S7-1200, S7-1500, S7-300, and S7-400 bus protocols. By comparing the data from each PLC controller and HMI in the field, the corresponding variable addresses are found and integrated into a unified WINCC platform. The process display is then associated with these address variables to achieve animation effects. The S7-200 / 200SMART, converted via a network coupler, is integrated with the WINCC platform through a TCP / IP driver to achieve data acquisition and process display association.

[0054] The inverter's operating data is transmitted to the OPC server via the Modbus TCP protocol, and the host computer can read the relevant data through the OPC server.

[0055] The above equipment data can be written into a local MySQL database by writing scripts based on display requirements to trigger timed or event-triggered operations, which can replace on-site staff in recording data.

[0056] In some embodiments, an IoT module is installed on one end of the SCADA server. The data collected by the SCADA server is uniformly connected to the IoT module and transmitted to the cloud. A dedicated interface and account and password information are configured, and a new alarm script is written in the IoT module. If the target device's operating status meets the alarm logic, an alarm is automatically triggered, such as automatically pushing alarm information to a mobile APP, WeChat official account, SMS, etc., so that users can be informed of alarm information in a timely manner.

[0057] The equipment monitoring system in this application solves the problem of inconsistent hardware interfaces, diverse bus protocols, and cross-network segment IP addresses of old PLC controllers in the digital transformation of various enterprises, which makes it impossible to implement monitoring on mobile devices.

[0058] Furthermore, in practical applications, some target equipment may experience unexpected alarm situations, such as no alarm information or no shutdown. This could lead to motor stalling or excessive process parameters, ultimately resulting in equipment damage and quality defects. To avoid this, some embodiments use an IoT module for secondary alarm detection. If a secondary alarm is deemed necessary, it is generated and uploaded to the cloud via an OPC server. Users can receive the secondary alarm information promptly via mobile apps, WeChat official accounts, SMS, etc., and then take appropriate action, such as shutting down the equipment, to prevent damage and ensure its safety.

[0059] In some embodiments, the process monitoring layer performs joint data monitoring and anomaly alarm judgment based on the second operating data corresponding to multiple target devices. Specifically, based on the experience of equipment operators operating the target devices for a long time, a set of multiple alarm logics more suitable for the irrigation device production process can be summarized for alarm purposes. It is even possible to automatically transmit some parameters to the downstream target devices based on the operating conditions of the upstream target devices. The second operating data of multiple target devices are monitored in conjunction, and anomaly alarm judgment is performed based on the set multiple alarm logic. If an anomaly is detected in any target device, a corresponding alarm is issued.

[0060] In summary, the equipment monitoring system in this application can achieve 24-hour online monitoring of various types of target equipment, such as production equipment and auxiliary equipment, without the need for manual data recording. Users can grasp production information in real time. At the same time, it can transmit data to the MES system for online calculation of production data, output, OEE (Overall Equipment Effectiveness). It not only meets the need for unified collection, monitoring and timely alarm push of target equipment operation data, but also realizes the determination of whether to issue an abnormal alarm based on multiple alarm logics according to production needs, and pushes the alarm information to the mobile terminal to notify the user in a timely manner, thereby facilitating the rapid handling of abnormal situations.

[0061] The workflow of the equipment monitoring system in this application is as follows:

[0062] 1. The equipment monitoring system converts the serial port of the old PLC controller (such as S7-200) CPU to an RJ45 network port and configures the IP address to connect to the floor switch.

[0063] 2. The network port of the new PLC controller (e.g., S7-1200, S7-1500) CPU is mapped to the industrial control network IP address (e.g., 172.10.XX) via a network coupler (one input, two outputs) to connect to the floor switch. The other network port continues to use the CPU's IP address (e.g., 192.168.XX) to communicate with the original HMI.

[0064] 3. Some instruments and frequency converters use conversion modules to convert Modbus RTU to Modbus TCP and are also connected to the floor switch.

[0065] 4. After all target devices are connected to the same network segment, they are connected to the aggregation switch and then to the SCADA server.

[0066] 5. The SCADA server converts various bus protocols to the OPC server and synchronizes the data to the database (such as SQL Server database). The MES system reads the data from the database for production output monitoring, recording the time of changes in equipment operating status, etc.

[0067] 6. The host computer communicates with the OPC server to read the target device's operating data and perform data monitoring and alarms.

[0068] 7. The IoT module uploads data to the cloud via the OPC server, allowing equipment operators, managers, and other users to monitor the operation of target equipment and receive alarm information through the cloud.

[0069] 8. Secondary alarm judgment is performed in the IoT module. After long-term use and exploration, some target devices will have unexpected alarm content. After the occurrence of this situation, there is no alarm information or shutdown operation, which may lead to motor stall or process parameters exceeding the standard, ultimately resulting in damage and quality defects of the target device. Secondary alarm is performed through the IoT module and the alert is uploaded to the cloud.

[0070] In the above embodiments, the equipment monitoring system includes a detection and execution layer for collecting first operating data corresponding to target equipment, wherein the target equipment includes equipment related to irrigation device production, and different target equipment corresponds to different network segments; a logic control layer connected to the detection and execution layer for acquiring the first operating data collected by the detection and execution layer; a network conversion layer connected to the logic control layer for converting the first operating data into second operating data under a unified network segment; a switch layer for connecting the second operating data to the process monitoring layer; and a process monitoring layer for monitoring the target equipment based on the second operating data and issuing alarms when abnormalities are detected. The monitoring process of the target equipment does not rely on manual experience, thus improving the efficiency and reliability of equipment monitoring.

[0071] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or system. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or system that includes that element.

[0072] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the scope of the technology disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application.

Claims

1. An equipment monitoring system, characterized in that, The equipment monitoring system includes: The detection execution layer is used to collect the first operating data corresponding to the target device, wherein the target device includes equipment related to the production of the irrigation device, and different target devices correspond to different network segments; A logic control layer, which is connected to the detection and execution layer, is used to acquire the first running data collected by the detection and execution layer; A network conversion layer, which is connected to the logic control layer, is used to convert the first running data into second running data under a unified network segment; A switch layer, which is used to connect the second operating data to the process monitoring layer; The process monitoring layer is used to monitor the target device based on the second operating data and to issue an alarm when an anomaly is detected.

2. The equipment monitoring system as described in claim 1, characterized in that, The logic control layer includes at least one of a PLC controller and a frequency converter, and the switch layer includes a floor switch, wherein the PLC controller or the frequency converter is connected to the floor switch.

3. The equipment monitoring system as described in claim 2, characterized in that, If the PLC controller body includes a serial port, a serial port / network port conversion module can be configured to expand the corresponding network port and then connected to the floor switch.

4. The equipment monitoring system as described in claim 2, characterized in that, When the PLC controller body includes a network port, and the corresponding IP address is not in the same network segment as the industrial control network IP address, the network port IP address is mapped to the industrial control network IP address using a network coupler before being connected to the floor switch.

5. The equipment monitoring system as described in claim 2, characterized in that, When the PLC controller body includes a network port and forms a local area network with other devices through a local switch, a network coupler is connected to the local switch. Based on the network coupler, the IP address of the network port is mapped to an industrial control network IP address and then connected to the floor switch.

6. The equipment monitoring system as described in claim 2, characterized in that, The frequency converter supports a serial communication protocol, which is converted into a TCP communication protocol before being connected to the floor switch.

7. The equipment monitoring system as described in claim 1, characterized in that, The process monitoring layer includes a SCADA server and an OPC server. The SCADA server performs data monitoring and alarms based on the second operating data, and uploads relevant monitoring information to the cloud through the OPC server. The relevant monitoring information includes at least one of operating status information and alarm information.

8. The equipment monitoring system as described in claim 7, characterized in that, The SCADA server is equipped with an IoT module on one end. The IoT module performs secondary alarm judgment. If it is determined that a secondary alarm is required, secondary alarm information is generated and uploaded to the cloud through the OPC server.

9. The equipment monitoring system as described in claim 1, characterized in that, The target devices include multiple devices, and the process monitoring layer performs joint data monitoring and anomaly alarm judgment based on the second operating data corresponding to the multiple target devices.

10. The equipment monitoring system according to any one of claims 1 to 9, characterized in that, The device monitoring system also includes a front-end display layer, which is used to display relevant monitoring information of the target device. The relevant monitoring information includes at least one of operating status information and alarm information.

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