A multifunctional device data collector and system

Abstract

The utility model provides a kind of equipment data multifunctional collector and system, collector includes power supply, PLC host computer, communication and extension module, module is achieved convenient plug and stable locking by row pin row female+elastic buckle, can flexible extension collection channel;Power module converts AC220V into stable DC24V power supply;System contains collector, relay group, internet of things module and cloud platform, pass through relay parallel lead out monitored equipment signal and realize electrical isolation, lossless collection operating state and yield data, PLC host computer is according to signal jump counting and classified storage data;Internet of things module supports ModbusTCP and ModbusRTU double communication mode, automatically switch when abnormal, data upload cloud platform realizes remote real-time monitoring.The utility model is adapted to multiple equipment scene, installation and maintenance are convenient, guarantee data collection accurate and continuous.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation and information technology, specifically to a multi-functional data acquisition device and system for equipment. Background Technology

[0002] In industrial production scenarios (such as textiles and machining), the operating status (start / stop) and output data of multiple pieces of equipment (e.g., sock knitting machines, machine tools) are the core basis for production scheduling, efficiency analysis, and cost control. There is an urgent need to achieve full-process monitoring through centralized and precise data collection. Currently, data collection in industrial settings mainly relies on traditional methods, which need to meet requirements such as parallel monitoring of multiple devices, real-time data transmission, and convenient installation and maintenance.

[0003] The shortcomings of existing technology: 1. Poor channel scalability: Traditional data acquisition equipment has a fixed number of input channels. When the number of monitored devices increases or new acquisition parameters need to be added, it is impossible to adapt to the needs through flexible expansion. The entire acquisition equipment needs to be replaced, resulting in increased usage costs and insufficient adaptability.

[0004] 2. Significant interference with existing equipment: Some data acquisition schemes require modifications to the control circuits, software programs, or wiring methods of the monitored equipment. This not only makes construction complex and time-consuming but may also disrupt the original operating logic of the equipment, posing safety hazards that could affect its normal operation.

[0005] 3. Inconvenient module connection and installation: The functional modules of traditional data acquisition equipment are mostly integrated designs or connected through complex wiring, making the disassembly, assembly and maintenance of modules cumbersome; moreover, the module fixing method lacks a stable mechanical locking structure, which is easily affected by factors such as field vibration, resulting in loose connections and thus affecting the stability of data acquisition.

[0006] Therefore, existing technologies have shortcomings and need further improvement. Utility Model Content

[0007] To address the problems existing in the prior art, this utility model provides a multi-functional data acquisition device and system.

[0008] To achieve the above objectives, the specific solution of this utility model is as follows: This utility model provides a multi-functional data acquisition device, including: Power supply module, PLC main unit module, communication module and expansion module; The input terminal of the power module is used to connect to an AC power source, and the output terminal provides a stable DC operating voltage. The PLC host module is equipped with a central processing unit, a storage unit, and several digital input channels and digital output channels. The PLC host module is electrically connected to the expansion module via a bus. The expansion module is used to expand the digital input channels of the PLC host module, so that the entire data acquisition unit forms multiple device data acquisition channels. The PLC host module is configured to store the status signals and counting signals acquired by the data acquisition channels of each device into the preset data register of the storage unit; The communication module is connected to the PLC host module. The communication module is equipped with an external communication interface for external host computers or IoT modules to access data registers, thereby enabling centralized collection of operating status and production data of multiple devices.

[0009] Furthermore, the power module, PLC host module, expansion module and communication module are each provided with pin headers on one side and pin headers on the other side; Adjacent modules are electrically connected by corresponding insertion of the pin headers of the preceding module and the female headers of the following module. The insertion structure of the pin headers and female headers also provides basic positioning for module docking, and together with the mechanical locking structure, it achieves stable combination, so that the number of modules can be increased or decreased as needed.

[0010] Furthermore, the power module, PLC host module, expansion module and communication module are provided with two symmetrically arranged L-shaped blocks on one side and two elastic buckles adapted to the L-shaped blocks on the other side. When modules are docked, the L-shaped latches of adjacent modules slide in along the latch guide structure and engage with the elastic latching part to achieve mechanical locking; when modules need to be separated, the two elastic latches are moved to the sides respectively to disengage the latching part from the L-shaped latches, and the modules can be separated along the guide direction.

[0011] Furthermore, the elastic buckle includes a fixing part, an elastic arm, and a snap-fit ​​end. The snap-fit ​​end is arrow-shaped, with its guide surface used to guide the L-shaped snap-fit ​​block to slide in, and its positioning surface used to fit and lock with the stepped surface of the L-shaped snap-fit ​​block to achieve reliable snap-fit.

[0012] Furthermore, the bottom of the power module, PLC host module, expansion module, and communication module are all provided with slots that are compatible with the strip fixing plate; through the sliding cooperation between the slots and the fixing plate, multiple modules are fixed to the strip fixing plate in sequence to achieve overall installation and positioning.

[0013] Furthermore, the input terminal of the power module is connected to AC220V mains power, and the AC220V is converted into a stable DC24V DC voltage through internal rectification, filtering and voltage regulation circuits, so as to provide DC24V power supply that meets the working requirements for the PLC main module, expansion module and communication module.

[0014] Furthermore, the multiple device data acquisition channels are grouped in such a way that each monitored device is configured with at least one power on / off status acquisition channel and one production count acquisition channel; The power on / off status acquisition channel is used to acquire the operating or shutdown status signals of the equipment; The production count acquisition channel is used to acquire the product count trigger signal of the equipment; The PLC host module maps the status signals of each power-on / off status acquisition channel to the first type of status data register, and maps the count values ​​of each production count acquisition channel to the second type of production data register, thereby realizing the classified storage of the operating status and cumulative production of each monitored device. The PLC host module is configured to: when it detects that the input signal of a certain production counting acquisition channel changes from an invalid state (such as low level) to an valid state (such as high level), treat the change as a valid count, and accumulate the value of the corresponding second type of production data register to update the equipment production data in real time.

[0015] This utility model also provides a multi-functional data acquisition system for equipment, including: Several monitored devices (such as multiple sock knitting machines), relay groups, IoT modules, cloud platform monitoring terminals, and multi-functional data acquisition devices for the above devices; in, Each monitored device has at least one power-on status indicator and one product counting sensor on its control board; the relay group includes a status relay and a counting relay corresponding to each monitored device, the coil of the status relay is connected in parallel with the power-on status indicator signal line of the corresponding monitored device, and the coil of the counting relay is connected in parallel with the product counting sensor signal line of the corresponding monitored device. The normally open contacts of each status relay and counting relay are connected to different device data acquisition channels of the device data multifunction acquisition unit through wiring terminals; The IoT module is electrically connected to the communication module of the device's multi-functional data collector through its own communication interface, and is used to periodically read the operating status data and production data in the data register and upload the data to the cloud platform monitoring terminal. The cloud platform monitoring terminal is used to centrally store, analyze, and visualize data from the Internet of Things module, enabling remote real-time monitoring of the operating status and output of several monitored devices.

[0016] Furthermore, the power-on status indicator lights and product counting sensors of each monitored device retain their original wiring methods and control logic; the coils of the status relays and counting relays are connected to the corresponding signal lines in parallel, and the normally open contacts of each relay are electrically isolated from the original circuit of the monitored device; through the above design, lossless acquisition of equipment operating status and production data can be achieved without altering the original hardware and software structure of the monitored device or affecting its normal operation.

[0017] Furthermore, the IoT module integrates a network port and an RS-485 interface, wherein: The network port is used to communicate with the communication module of the device's multi-functional data acquisition unit (Modbus TCP slave mode) in Modbus TCP master mode; The RS-485 interface is used to communicate with the communication module of the device's data multifunction acquisition unit (ModbusRTU slave mode) in Modbus RTU master mode. The IoT module is configured to detect the communication status with the data collector in real time. When an abnormal ModbusTCP communication is detected, it automatically switches to ModbusRTU communication mode and reports the communication switching status to the cloud platform monitoring terminal. The cloud platform monitoring terminal can issue communication mode switching commands according to actual needs, controlling the IoT module to switch between two communication modes to ensure the continuity and reliability of data upload.

[0018] The technical solution of this utility model has the following beneficial effects: 1. Flexible channel expansion and strong adaptability: Through the bus connection design between the PLC host module and the expansion module, the expansion module can be flexibly added or removed according to the number of monitored devices and the data acquisition requirements, quickly expanding the digital input channels without replacing the entire set of acquisition equipment. This effectively adapts to scenarios where production scale is dynamically adjusted, reducing equipment upgrade and usage costs.

[0019] 2. Convenient module installation and maintenance, stable and reliable connection: Each functional module adopts a "pin header-female header" plug-in structure combined with an L-shaped locking block and arrow-shaped elastic buckle mechanical locking design, which not only realizes the quick docking and separation of modules, but also ensures the connection stability through the positioning surface fitting and locking; at the same time, the sliding cooperation design of the bottom slot of the module and the strip fixing plate facilitates the overall installation and positioning of multiple modules, has strong anti-vibration interference capability, and greatly simplifies the installation, maintenance and repair process.

[0020] 3. Non-destructive data acquisition design, without affecting the operation of existing equipment: The status indicator lights and counting sensor signal lines of the monitored equipment are led out in parallel through relay groups, and the normally open contacts of the relays are electrically isolated from the original circuit. There is no need to modify the original hardware and software structure, wiring method and control logic of the equipment. Under the premise of ensuring the normal operation of the equipment, the safe acquisition of operating status and output data can be achieved, which is suitable for various in-use industrial equipment transformation scenarios. Attached Figure Description

[0021] Figure 1 This is a three-dimensional representation of the power module of this utility model. Figure 1 ; Figure 2 This is a three-dimensional representation of the power module of this utility model. Figure 2 ; Figure 3 This is a three-dimensional representation of the PLC main unit module of this utility model. Figure 1 ; Figure 4 This is a three-dimensional representation of the PLC main unit module of this utility model. Figure 2 ; Figure 5 This is a three-dimensional representation of the communication model of this utility model. Figure 1 ; Figure 6 This is a three-dimensional representation of the communication model of this utility model. Figure 2 ; Figure 7 This is a three-dimensional extension module of the present invention. Figure 1 ; Figure 8 This is a three-dimensional extension module of the present invention. Figure 2 ; Figure 9 This is a schematic diagram of signal output and acquisition for a single sock knitting machine according to Embodiment 1 of this utility model; Figure 10 This is a schematic diagram of power on / off status signal acquisition according to Embodiment 1 of this utility model; Figure 11 This is a schematic diagram of the production signal acquisition in Embodiment 1 of this utility model; Attached image captions: 1. Power supply module; 2. PLC main unit module; 3. Communication module; 4. Expansion module; 5. Pin header; 6. Female header; 7. L-shaped locking block; 8. Elastic buckle; 9. Slot. Detailed Implementation

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, not the entire structure.

[0023] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0024] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0025] In the description of this embodiment, the terms "upper," "lower," "front," "rear," "left," and "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0026] Combination Figures 1-11 As shown, this utility model provides a multi-functional data acquisition device, comprising: Power supply module 1, PLC main unit module 2, communication module 3, and expansion module 4; The input terminal of the power module 1 is used to connect to an AC power source, and the output terminal provides a stable DC operating voltage. The PLC host module 2 is internally equipped with a central processing unit, a storage unit, and several digital input channels and digital output channels. The PLC host module 2 is electrically connected to the expansion module 4 via a bus. The expansion module 4 is used to expand the digital input channels of the PLC host module 2, so that the entire data acquisition unit forms multiple device data acquisition channels. The PLC host module 2 is configured to store the status signals and counting signals acquired by the data acquisition channels of each device into the preset data register of the storage unit; The communication module 3 is connected to the PLC host module 2. The communication module 3 is equipped with an external communication interface for external host computers or IoT modules to access data registers, thereby realizing centralized collection of operating status and production data of multiple devices.

[0027] The power module 1, PLC host module 2, expansion module 4 and communication module 3 are each provided with a pin header 5 on one side and a female header 6 on the other side. Adjacent modules are connected by inserting the pin header 5 of the preceding module into the corresponding female header 6 of the following module to achieve electrical connection between the modules; the insertion structure of the pin header 5 and female header 6 also provides basic positioning for module docking, and together with the mechanical locking structure, achieves stable combination, so as to increase or decrease the number of modules as needed.

[0028] The power module 1, PLC host module 2, expansion module 4 and communication module 3 are provided with two symmetrically arranged L-shaped blocks 7 on one side and two elastic buckles 8 adapted to the L-shaped blocks 7 on the other side. When modules are docked, the L-shaped locking blocks 7 of adjacent modules slide in along the locking guide structure and engage with the elastic locking part of the elastic locking buckle 8 to achieve mechanical locking; when modules need to be separated, the two elastic locking buckles 8 are moved to the sides respectively, so that the locking part of the elastic locking buckle 8 disengages from the L-shaped locking blocks 7, and the modules can be separated along the guide direction.

[0029] The elastic buckle 8 includes a fixing part, an elastic arm, and a snap-fit ​​end. The snap-fit ​​end is arrow-shaped, and its guide surface is used to guide the L-shaped snap-fit ​​block 7 to slide in. Its positioning surface is used to fit and lock with the stepped surface of the L-shaped snap-fit ​​block 7 to achieve reliable snap-fit.

[0030] The bottom of the power module 1, PLC host module 2, expansion module 4 and communication module 3 are all provided with slots 9 that are adapted to the strip fixing plate; through the sliding cooperation between the slots 9 and the fixing plate, multiple modules are fixed to the strip fixing plate in sequence to achieve overall installation and positioning.

[0031] The power module 1 is connected to AC220V AC mains power at its input terminal. Through internal rectification, filtering and voltage regulation circuits, AC220V is converted into a stable DC24V DC voltage, providing DC24V power supply that meets the working requirements for PLC main module 2, expansion module 4 and communication module 3.

[0032] The multiple device data acquisition channels are grouped in such a way that each monitored device is configured with at least one power on / off status acquisition channel and one production count acquisition channel; The power on / off status acquisition channel is used to acquire the operating or shutdown status signals of the equipment; The production count acquisition channel is used to acquire the product count trigger signal of the equipment; The PLC host module 2 maps the status signals of each power-on / off status acquisition channel to the first type of status data register, and maps the count values ​​of each production count acquisition channel to the second type of production data register, thereby realizing the classified storage of the operating status and cumulative production of each monitored device. The PLC host module 2 is configured to: when the input signal of a certain production counting acquisition channel changes from an invalid state (such as low level) to an valid state (such as high level), the change is taken as a valid count, and the value of the corresponding second type of production data register is accumulated to update the equipment production data in real time.

[0033] This utility model also provides a multi-functional data acquisition system for equipment, including: Several monitored devices (such as multiple sock knitting machines), relay groups, IoT modules, cloud platform monitoring terminals, and multi-functional data acquisition devices for the above devices; in, Each monitored device has at least one power-on status indicator and one product counting sensor on its control board; the relay group includes a status relay and a counting relay corresponding to each monitored device, the coil of the status relay is connected in parallel with the power-on status indicator signal line of the corresponding monitored device, and the coil of the counting relay is connected in parallel with the product counting sensor signal line of the corresponding monitored device. The normally open contacts of each status relay and counting relay are connected to different device data acquisition channels of the device data multifunction acquisition unit through wiring terminals; The IoT module is electrically connected to the communication module 3 of the device data multi-function collector through its own communication interface, and is used to periodically read the operating status data and production data in the data register and upload the data to the cloud platform monitoring terminal. The cloud platform monitoring terminal is used to centrally store, analyze, and visualize data from the Internet of Things module, enabling remote real-time monitoring of the operating status and output of several monitored devices.

[0034] The power-on status indicator lights and product counting sensors of each monitored device retain their original wiring methods and control logic; the coils of the status relays and counting relays are connected to the corresponding signal lines in parallel, and the normally open contacts of each relay are electrically isolated from the original circuit of the monitored device; through the above design, the lossless acquisition of equipment operating status and production data can be achieved without changing the original hardware and software structure of the monitored device or affecting its normal operation.

[0035] The IoT module integrates a network port and an RS-485 interface, wherein: The network port is used to communicate with the communication module 3 (Modbus TCP slave mode) of the device data multi-function acquisition unit in Modbus TCP master mode; The RS-485 interface is used to communicate with the communication module 3 (ModbusRTU slave mode) of the device data multifunction acquisition unit in Modbus RTU master mode; The IoT module is configured to detect the communication status with the data collector in real time. When an abnormal ModbusTCP communication is detected, it automatically switches to ModbusRTU communication mode and reports the communication switching status to the cloud platform monitoring terminal. The cloud platform monitoring terminal can issue communication mode switching commands according to actual needs, controlling the IoT module to switch between two communication modes to ensure the continuity and reliability of data upload.

[0036] The principle of this utility model is as follows: This invention achieves accurate, stable, and remote acquisition and monitoring of the operating status and production data of multiple devices through a full-link collaborative design of "module combination - lossless acquisition - data processing - dual-mode transmission - cloud monitoring". The specific working principle is as follows: I. System Setup and Power Supply Mechanism Module Combination and Fixing: The power module 1, PLC host module 2, expansion module 4, and communication module 3 achieve rapid electrical connection through the "pin header 5-female header 6" plug-in structure. At the same time, mechanical fixation is completed by the guide sliding of L-shaped card block 7 and arrow-shaped elastic buckle 8 and the locking of the positioning surface. Each module achieves overall installation and positioning by sliding cooperation with the strip fixing plate through the bottom card slot 9. The number of expansion modules 4 can be flexibly increased or decreased according to the number of monitored devices, and the number of acquisition channels can be adjusted.

[0037] Stable power supply output: Power module 1 is connected to AC220V mains power, which is converted into a stable DC24V DC voltage through internal rectification, filtering and voltage regulation circuits, providing a unified power supply that meets the working requirements for PLC main module 2, expansion module 4 and communication module 3, ensuring the stable operation of each module.

[0038] II. Non-destructive data acquisition mechanism for equipment Signal output and electrical isolation: Each monitored device does not require modification to its original hardware and software structure and control logic. Data acquisition is achieved through relay groups: the status relay coil is connected in parallel with the device's power-on status indicator signal line, and the counting relay coil is connected in parallel with the device's product counting sensor signal line; the normally open contacts of the relays are electrically isolated from the original circuit of the device, and the signal is output only through contact action, avoiding interference with the normal operation of the device during the acquisition process.

[0039] Data Acquisition Channel Configuration: The data acquisition unit is connected to the PLC host module 2 and the expansion module 4 via a bus to form multiple device data acquisition channels. They are grouped according to the rule of "at least one power on / off status acquisition channel and one production count acquisition channel for each device" and connected to the normally open contacts of the corresponding relays to realize independent acquisition of the status and production signals of a single device.

[0040] III. Data Processing and Classification Storage Mechanism Signal detection and counting logic: PLC host module 2 monitors the signals of each acquisition channel in real time: the power on / off status acquisition channel directly acquires the equipment running / stop status signal; the production counting acquisition channel detects signal transitions. When the input signal changes from an invalid state (such as low level) to an valid state (such as high level), it is determined as a valid count, triggering the corresponding production register value to accumulate and updating the equipment production data in real time.

[0041] Categorized storage management: PLC host module 2 categorizes and maps the data collected from each channel to two types of preset registers in the storage unit: the power on / off status signal is stored in the first type of status data register, and the production count value is stored in the second type of production data register, realizing the association storage of the operating status of a single device with the cumulative production, which facilitates quick query and data analysis.

[0042] IV. Data Transmission and Communication Guarantee Mechanism Dual-mode communication connection: The IoT module establishes a connection with the collector's communication module 3 through the communication interface, supporting two communication modes: communicating with the collector in Modbus TCP master mode (Modbus TCP slave mode) via the network port, or communicating with the collector in Modbus RTU master mode (Modbus RTU slave mode) via the RS-485 interface.

[0043] Communication reliability assurance: The IoT module monitors the communication status in real time. When ModbusTCP communication is abnormal, it automatically switches to ModbusRTU mode and reports the switching status. The cloud platform monitoring terminal can issue instructions to manually control the switching of communication modes according to actual needs, ensuring uninterrupted data transmission.

[0044] V. Centralized Cloud Monitoring Mechanism The IoT module periodically reads data from the two types of data registers of the collector and uploads the operating status and output data of multiple devices to the cloud platform monitoring terminal. The cloud platform centrally stores and statistically analyzes the received data and displays it through a visual interface, realizing remote real-time monitoring of all monitored devices and providing data support for production scheduling and management decisions.

[0045] Example 1: This implementation provides a digital monitoring system designed to upgrade existing sock knitting machine production lines digitally at low cost and without damage. The system mainly consists of three parts: a field data acquisition layer, a network transmission layer, and a cloud platform monitoring layer.

[0046] 1. Field data acquisition layer: This includes relay groups for signal output, PLC controllers and their expansion modules; the PLC acts as a slave station, responsible for collecting real-time data from 16 sock knitting machines.

[0047] 2. Network transmission layer: includes an IoT module; this module acts as the master station, communicating with the PLC through dual communication channels (Modbus TCP and Modbus RTU) and uploading data to the cloud platform.

[0048] 3. Cloud Platform Monitoring Layer: Provides a remotely accessible cloud service platform for centrally displaying the status and data of all sock knitting machines.

[0049] Hardware connection and signal acquisition like Figure 9 The diagram shown illustrates the signal extraction and acquisition process for a single sock knitting machine. While the sock knitting machine itself lacks a standard external data interface, its control board is equipped with a product counting sensor and a power-on status indicator. To achieve lossless data acquisition, this invention employs the following method: Connect a relay in parallel to the power-on status indicator signal line of each sock knitting machine (e.g., Figure 9 and Figure 10 The status relay K1 in the system is powered by a coil. When the indicator light illuminates (the machine is powered on), relay K1 is energized and engages.

[0050] Similarly, a relay (e.g., ...) is connected in parallel to the product count sensor signal line for each sock knitting machine. Figure 11 The counting relay K17 in the middle is powered by the coil of the relay; each time a sock is produced, the counting sensor is triggered once, and the counting relay K17 is energized once.

[0051] The normally open contacts of status relay K1 and counting relay K17 are led out as dry contact signals and connected to the input points of the PLC respectively.

[0052] The system's PLC core controller uses the L02S-32MT model as the main unit (with 16 inputs / 16 outputs), and expands to 16 input points through the L02S-16EX expansion module, providing a total of 32 digital input points, sufficient to connect 16 sock knitting machines (each occupying 2 input points). The entire system is powered by the L02-60P power module, which converts AC220V mains power to a stable DC24V power supply to power the PLC, expansion modules, and external relay coils. Figure 9 As shown, the signals from the 16 sock knitting machines are connected to the PLC in the above manner.

[0053] like Figure 10 As shown, the power on / off status signal acquisition is as follows: One end of the contact of the running status relay K1 of the first sock knitting machine (machine 1) is connected to the common terminal (COM) of the PLC, and the other end is connected to input point X0 of the main PLC (L02S-32MT). Similarly, the status signals of machines 2 to 16 are sequentially connected to input points X1 to X7 and X10 to X17 of the main PLC. The PLC determines the power on / off status of the sock knitting machine by detecting whether this input point is conductive (conductive means on, disconnected means off).

[0054] like Figure 11 As shown, the production signal acquisition is as follows: one end of the contact of the counting relay K17 of the first sock knitting machine (machine 1) is connected to the common terminal (S / S) of the expansion module, and the other end is connected to the input point X20 of the expansion module (L02S-16EX); similarly, the counting signals of machines 2 to 16 are connected to the input points X21 to X37 of the expansion module in sequence; the PLC internal program records each transition of the input point from "off" to "on" as a valid count and accumulates them to obtain the real-time production of each sock knitting machine.

[0055] Data transmission and communication The PLC's internal programming monitors and accumulates the status of all input points, storing this data in specific data registers. The IoT module communicates with the PLC (as a Modbus slave) via an Ethernet port (RJ45) using the Modbus TCP protocol, periodically polling the PLC's data registers and uploading the data to the cloud platform; this is the normal operating channel. Simultaneously, the system has a backup communication channel; the IoT module can also communicate with the PLC via its RS-485 interface using the Modbus RTU protocol. If a network interface failure causes Modbus TCP communication to be interrupted, the administrator can remotely issue a command from the cloud platform to switch the communication channel to the RS-485 interface, continuing data upload using the Modbus RTU protocol, ensuring the reliability of system communication.

[0056] Cloud platform monitoring The cloud platform receives data uploaded from various IoT modules; the platform can manage multiple IoT modules (i.e., multiple PLC monitoring nodes); the platform constructs a visualized configuration monitoring screen, displaying the on / off status and cumulative output of each sock knitting machine in real time in the form of indicator lights, data tables, etc.; users do not need to install special software, they can log in to the cloud platform anytime and anywhere through a computer browser or WeChat mini program to achieve centralized and visualized monitoring and management of sock knitting machine production lines scattered in different locations.

[0057] Innovation The innovation of this implementation method lies in achieving a completely non-destructive digital transformation of traditional sock knitting machines. By "stealing" signals from the machine's original indicator lights and sensors through parallel connection of external relays, it does not interfere with any software or hardware of the original control system of the sock knitting machine, thus solving the problem of digital transformation of old equipment. At the same time, the dual communication channel design enhances the robustness of the system; the entire solution is quick to deploy and low in cost, greatly improving the efficiency of production line management.

[0058] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. All equivalent structural transformations made under the inventive concept of the present utility model using the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the protection scope of the present utility model.

Claims

1. A multi-functional data acquisition device, characterized in that, include: Power supply module, PLC main unit module, communication module and expansion module; The input terminal of the power module is used to connect to an AC power source, and the output terminal provides a stable DC operating voltage. The PLC host module is equipped with a central processing unit, a storage unit, and several digital input channels and digital output channels. The PLC host module is electrically connected to the expansion module via a bus. The expansion module is used to expand the digital input channels of the PLC host module, so that the entire data acquisition unit forms multiple device data acquisition channels. The PLC host module is configured to store the status signals and counting signals acquired by the data acquisition channels of each device into the preset data register of the storage unit; The communication module is connected to the PLC host module. The communication module is equipped with an external communication interface for external host computers or IoT modules to access data registers, thereby enabling centralized collection of operating status and production data of multiple devices.

2. The device data multi-functional acquisition device according to claim 1, characterized in that, The power module, PLC host module, expansion module and communication module are all equipped with pin headers on one side and pin headers on the other side. Adjacent modules are electrically connected by corresponding insertion of the pin headers of the preceding module and the female headers of the following module. The insertion structure of the pin headers and female headers also provides basic positioning for module docking, and together with the mechanical locking structure, it achieves stable combination, so that the number of modules can be increased or decreased as needed.

3. The device data multi-functional acquisition device according to claim 1, characterized in that, The power module, PLC host module, expansion module and communication module are provided with two symmetrically arranged L-shaped blocks on one side and two elastic buckles that are adapted to the L-shaped blocks on the other side. When modules are docked, the L-shaped latches of adjacent modules slide in along the latch guide structure and engage with the elastic latching part to achieve mechanical locking; when modules need to be separated, the two elastic latches are moved to the sides respectively to disengage the latching part from the L-shaped latches, and the modules can be separated along the guide direction.

4. The device data multi-functional acquisition device according to claim 3, characterized in that, The elastic buckle includes a fixing part, an elastic arm, and a snap-fit ​​end. The snap-fit ​​end is arrow-shaped, with its guide surface used to guide the L-shaped snap-fit ​​block to slide in, and its positioning surface used to fit and lock with the stepped surface of the L-shaped snap-fit ​​block to achieve reliable snap-fit.

5. The device data multi-functional acquisition device according to claim 1, characterized in that, The bottom of the power module, PLC host module, expansion module and communication module are all provided with slots that are compatible with the strip fixing plate; through the sliding cooperation between the slots and the fixing plate, multiple modules are fixed to the strip fixing plate in sequence to achieve overall installation and positioning.

6. The device data multi-functional acquisition device according to claim 1, characterized in that, The power module's input terminal is connected to AC220V AC mains power. Through internal rectification, filtering, and voltage regulation circuits, AC220V is converted into a stable DC24V DC voltage, providing DC24V power supply that meets the operating requirements for the PLC main module, expansion module, and communication module.

7. The device data multi-functional acquisition device according to claim 1, characterized in that, The multiple device data acquisition channels are grouped in such a way that each monitored device is configured with at least one power on / off status acquisition channel and one production count acquisition channel; The power on / off status acquisition channel is used to acquire the operating or shutdown status signals of the equipment; The production count acquisition channel is used to acquire the product count trigger signal of the equipment; The PLC host module maps the status signals of each power-on / off status acquisition channel to the first type of status data register, and maps the count values ​​of each production count acquisition channel to the second type of production data register, thereby realizing the classified storage of the operating status and cumulative production of each monitored device. The PLC host module is configured to: when it detects that the input signal of a certain production counting acquisition channel changes from an invalid state to an valid state, treat the change as a valid count, and accumulate the value of the corresponding second type of production data register to update the equipment production data in real time.

8. A multi-functional data acquisition system for equipment, characterized in that, include: Several monitored devices, relay groups, IoT modules, cloud platform monitoring terminals, and the device data multi-functional acquisition device as described in any one of claims 1 to 7; in, Each monitored device has at least one power-on status indicator and one product counting sensor on its control board; the relay group includes a status relay and a counting relay corresponding to each monitored device, the coil of the status relay is connected in parallel with the power-on status indicator signal line of the corresponding monitored device, and the coil of the counting relay is connected in parallel with the product counting sensor signal line of the corresponding monitored device. The normally open contacts of each status relay and counting relay are connected to different device data acquisition channels of the device data multifunction acquisition unit through wiring terminals; The IoT module is electrically connected to the communication module of the device's multi-functional data collector through its own communication interface, and is used to periodically read the operating status data and production data in the data register and upload the data to the cloud platform monitoring terminal. The cloud platform monitoring terminal is used to centrally store, analyze, and visualize data from the Internet of Things module, enabling remote real-time monitoring of the operating status and output of several monitored devices.

9. The multi-functional data acquisition system for equipment according to claim 8, characterized in that, The power-on status indicator lights and product counting sensors of each monitored device retain their original wiring methods and control logic; the coils of the status relays and counting relays are connected to the corresponding signal lines in parallel, and the normally open contacts of each relay are electrically isolated from the original circuit of the monitored device; through the above design, the lossless acquisition of equipment operating status and production data can be achieved without changing the original hardware and software structure of the monitored device or affecting its normal operation.

10. The multi-functional data acquisition system for equipment according to claim 8, characterized in that, The IoT module integrates a network port and an RS-485 interface, wherein: The network port is used to communicate with the communication module of the device's multi-functional data acquisition unit in Modbus TCP master mode; The RS-485 interface is used to communicate with the communication module of the device's multi-function data acquisition unit in ModbusRTU master mode. The IoT module is configured to detect the communication status with the data collector in real time. When an abnormal ModbusTCP communication is detected, it automatically switches to ModbusRTU communication mode and reports the communication switching status to the cloud platform monitoring terminal. The cloud platform monitoring terminal can issue communication mode switching commands according to actual needs, controlling the IoT module to switch between two communication modes to ensure the continuity and reliability of data upload.

Images