A workshop production state acquisition system based on Zigbee wireless communication

Abstract

The utility model provides a workshop production state acquisition system based on zigbee wireless communication belongs to detection equipment technical field, and this system includes: a plurality of terminal nodes, a plurality of router nodes, coordinator node and host computer, the coordinator node creates zigbee wireless network, each terminal node gathers the production state data of equipment in workshop and forms data packet, and is transmitted to corresponding router node through zigbee wireless network, each router node forwards the received data packet to coordinator node through zigbee wireless network, a plurality of router nodes are connected through zigbee wireless network, the coordinator node sends the received data packet to host computer. This system realizes the real -time transmission of monitoring data through zigbee wireless network, and terminal node does not need to rely on wired connection, and the data of sensor acquisition can be directly wireless sent, avoids the complex wiring problem, reduces deployment cost simultaneously, improves system flexibility.

Description

Technical Field

[0001] This utility model relates to the field of detection equipment technology, and in particular to a workshop production status acquisition system based on Zigbee wireless communication. Background Technology

[0002] In industrial automated production, real-time monitoring and statistical analysis of production status within the workshop are crucial for achieving intelligent manufacturing. Traditional data acquisition systems typically rely on infrared diffuse reflection proximity sensor networks to collect information such as equipment operating parameters, environmental conditions, and material flow in real time, and then transmit this data to a host computer for processing and analysis. The reliability and real-time performance of such systems directly impact the efficiency of production management; therefore, the stability and flexibility of the transmission method are particularly important.

[0003] Currently, production status statistics systems in workshops primarily employ wired transmission. Infrared diffuse reflection proximity sensors are connected to a processor or host computer via wired communication cables (such as RS-485, CAN bus, or industrial Ethernet) to achieve centralized data acquisition and processing. This method utilizes mature industrial communication protocols, ensuring data transmission stability and anti-interference capabilities to a certain extent, and has been widely applied in monitoring scenarios for fixed equipment.

[0004] However, the above-mentioned wired transmission mode has the following technical defects: (1) High deployment cost. Each additional infrared diffuse reflection proximity sensor or processor node requires the laying of a dedicated communication cable, which leads to a significant increase in the overall system cost as the scale grows. At the same time, the cable occupies production space; (2) Difficult to upgrade. When the system is expanded or adjusted in the later stage, it is necessary to rewire, which affects the original deployment structure. The construction is complicated and easily interferes with normal production; (3) The placement of infrared diffuse reflection proximity sensors is limited. The wired connection method restricts the installation position of infrared diffuse reflection proximity sensors, making it difficult to adapt to the monitoring needs of mobile devices (such as feeding carts and mobile storage pallets), thus limiting the applicability and flexibility of the system.

[0005] Therefore, there is an urgent need for a production status acquisition system that is low in deployment cost, easily scalable, and supports mobile monitoring. Summary of the Invention

[0006] This invention creates a Zigbee wireless network by setting up a regulator node, and forwards data packets from the routing node to the host computer, thereby enabling scalable terminal nodes.

[0007] The technical means adopted in this utility model are as follows: A workshop production status acquisition system based on Zigbee wireless communication includes: Several terminal nodes, several router nodes, coordinator nodes, and a host computer; The coordinator node creates a Zigbee wireless network; Each terminal node collects production status data of the equipment in the workshop, forms data packets, and transmits them to the corresponding router node via the Zigbee wireless network. Each router node forwards the received data packets to the coordinator node via a Zigbee wireless network; several router nodes are connected to each other via a Zigbee wireless network. The coordinator node sends the received data packets to the host computer.

[0008] Furthermore, the terminal node includes: The system includes a processor, a first infrared diffuse reflection proximity sensor, a second infrared diffuse reflection proximity sensor, an RF input module, and a clock module. The first infrared diffuse reflection proximity sensor and the second infrared diffuse reflection proximity sensor are arranged along the component transport route. The electrical signal triggered by the first infrared diffuse reflection proximity sensor and the electrical signal triggered by the second infrared diffuse reflection proximity sensor are used to measure the part's electrical signal. The radio frequency module collects the ID information of the component and sends it to the processor; The clock module provides real-time clock information to the processor; The processor receives the electrical signal triggered by the first infrared diffuse reflection proximity sensor and the electrical signal triggered by the second infrared diffuse reflection proximity sensor, and outputs a component storage signal or a component retrieval signal. The processor uses the storage or retrieval signals of the parts, the ID information of the parts, and the real-time clock information as production status data of the equipment to form a data packet.

[0009] Furthermore, the power supply method of the terminal node includes: battery power or power cord power.

[0010] Furthermore, the infrared diffuse reflection proximity sensor and the processor are connected by wires.

[0011] Furthermore, the straight-line distance between the terminal node and the router node is less than 10 meters.

[0012] Furthermore, the terminal node also includes: Key input module and display module; The key input module adjusts and sets the terminal node; The display module is responsible for displaying setting information and production information.

[0013] Compared with the prior art, the present invention has the following advantages: Real-time transmission of monitoring data is achieved through the Zigbee wireless network. Terminal nodes do not need to rely on wired connections, and the data collected by the sensors can be sent directly wirelessly, avoiding complex wiring problems, reducing deployment costs, and improving system flexibility.

[0014] The architecture of this system supports modular expansion. If an upgrade or modification is needed, only new router nodes or terminal nodes need to be added to the existing Zigbee network. There is no need to rewire or adjust the original hardware structure, which greatly reduces maintenance and modification costs.

[0015] Terminal nodes can be battery powered, eliminating the dependence on fixed power sources and enabling them to operate stably on mobile equipment (such as feeding trolleys, mobile storage pallets, etc.), thus expanding the application scope of the system on the production site.

[0016] Based on the Zigbee network architecture, this system can support wireless networking capabilities of up to 60,000 nodes, meeting the high-density data acquisition needs in industrial environments and is suitable for information monitoring and management in complex production scenarios.

[0017] Zigbee networks feature self-organizing and dynamic routing capabilities. When individual nodes in the network fail, the system can automatically select the optimal transmission path to ensure stable data transmission and significantly improve the network's reliability and anti-interference ability.

[0018] In summary, this system effectively solves the problems of high cost, limited deployment, and difficult expansion associated with wired transmission methods. It has advantages such as convenient installation, flexible expansion, strong adaptability, and high reliability, and can be widely used in fields such as industrial automation and intelligent manufacturing to improve the efficiency and intelligence level of production data acquisition. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the workshop production status acquisition system based on Zigbee wireless communication according to this utility model.

[0021] Figure 2 This is a schematic diagram of the deployment of the infrared diffuse reflection proximity sensor in the terminal node of this utility model.

[0022] In the diagram: 1. Terminal node; 2. Router power cable; 3. Coordinator node; 4. Host computer; 11. First infrared diffuse reflection proximity sensor; 12. Second infrared diffuse reflection proximity sensor. Detailed Implementation

[0023] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0026] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0027] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms 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, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0028] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0029] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0030] like Figure 1 As shown, this utility model provides a workshop production status acquisition system based on Zigbee wireless communication, including: several terminal nodes 1, several router nodes 2, coordinator nodes 3, and a host computer 4.

[0031] The host computer 4 connects to the coordinator node 3. The coordinator node 3 creates a Zigbee wireless network and connects to all router nodes 2, forwarding the data packets of the router nodes 2 to the host computer 4. Terminal node 1 collects production status data of equipment in the workshop, forms data packets, and transmits them to router node 2 via the Zigbee wireless network; router node 2 forwards the data packets to coordinator node 3 via the Zigbee wireless network.

[0032] Example 1 like Figure 1As shown, this utility model provides a workshop production status acquisition system based on Zigbee wireless communication, including: several terminal nodes 1, several router nodes 2, coordinator nodes 3, and a host computer 4.

[0033] The host computer 4 connects to the coordinator node 3. The coordinator node 3 creates a Zigbee wireless network and connects to all router nodes 2, forwarding the data packets of the router nodes 2 to the host computer 4. Terminal node 1 collects production status data of equipment in the workshop, forms data packets, and transmits them to router node 2 via the Zigbee wireless network; router node 2 forwards the data packets to coordinator node 3 via the Zigbee wireless network.

[0034] Terminal node 1 includes: a processor, a first infrared diffuse reflection proximity sensor 11, a second infrared diffuse reflection proximity sensor 12, an RF input module, a clock module, and a display module; like Figure 2 As shown, the first infrared diffuse reflection proximity sensor 11 and the second infrared diffuse reflection proximity sensor 12 are arranged along the part transport route. The trigger electrical signal of the component triggering the first infrared diffuse reflection proximity sensor and the trigger electrical signal of the component triggering the second infrared diffuse reflection proximity sensor are transmitted to the processor; The radio frequency module collects the ID information of the component and sends it to the processor; The clock module provides real-time clock information to the processor; the processor determines whether the part is stored or retrieved by the triggering time sequence of the triggering electrical signals of the first infrared diffuse reflection proximity sensor and the second infrared diffuse reflection proximity sensor; the processor uses the storage or retrieval of the part, the part's ID information, and the real-time clock information as production status data of the equipment to form a data packet.

[0035] When an object approaches, the infrared diffuse reflection proximity sensor triggers an electrical signal. Terminal node 1 determines whether to store or retrieve a part in the part storage area based on the order of the electrical signals triggered by the two infrared diffuse reflection proximity sensors. When storing a part, the order in which the infrared diffuse reflection proximity sensors are triggered is: first infrared diffuse reflection proximity sensor 11 and second infrared diffuse reflection proximity sensor 12. When retrieving a part, the order in which the infrared diffuse reflection proximity sensors are triggered is: second infrared diffuse reflection proximity sensor 12 and first infrared diffuse reflection proximity sensor 11.

[0036] Terminal node 1 sends information such as the stored or retrieved parts, the part ID, and the date and time of completion of the current process as data packets via the Zigbee wireless network. Host computer 4 receives the data packets, extracts different data information, and displays the information in its software.

[0037] In this embodiment, the terminal node is powered by either battery or wired power.

[0038] For infrared diffuse reflection proximity sensors with fixed locations and where power lines are available, the terminal nodes can be powered by wired power supplies.

[0039] For situations where the infrared diffuse reflection proximity sensor needs to be moved, the terminal node can be battery powered.

[0040] In Zigbee wireless networks, end nodes can enter a sleep state when not in use. Combined with the low-power characteristics of the communication protocol itself, this allows end nodes to be powered by batteries. Battery-powered end nodes can operate for up to several months without battery replacement. Such a long operating time in battery-powered mode is something that wireless communication devices such as WiFi and Bluetooth cannot achieve.

[0041] In the terminal node, all modules except the infrared diffuse reflection proximity sensor module are housed inside the node's plastic housing. Only the infrared diffuse reflection proximity sensor module is mounted outside the housing. The infrared diffuse reflection proximity sensor is connected to the node's processor via a wire. The node is positioned near the infrared diffuse reflection proximity sensor.

[0042] Router nodes and coordinator nodes do not collect data; they only receive data in real time and forward it.

[0043] Example 2 A workshop production status acquisition system based on Zigbee wireless communication, preferably, the terminal node 1 is arranged within a preset distance range of the infrared diffuse reflection proximity sensor.

[0044] Preferably, terminal node 1 further includes: a button input module and a display module; the button input module adjusts and sets the terminal node, and the display module is responsible for displaying setting information and production information.

[0045] Router node 2 is connected to a power supply line and can be installed on the ceiling or pillars of the production workshop. Preferably, the distance between terminal node 1 and the connected router node 2 is less than 10m.

[0046] To ensure the communication quality of the entire Zigbee wireless network, the routing nodes 2 are connected in a mesh structure.

[0047] Preferably, only one coordinator 3 is deployed in the system and connected to the host computer 4, and is set within the pre-distance range of the host computer.

[0048] Preferably, a terminal node is installed at a key part quantity monitoring location, which can monitor the number of parts that have been processed in real time. This could include the number of products processed by a particular machine tool or the number of products processed in a specific process step.

[0049] The monitoring interface allows users to view the operating status of each machine tool in the workshop (such as whether it is running or stopped) and the number of parts that have been processed.

[0050] While viewing data on the host computer, you can check the trend of part quantity changes by viewing historical curves, which facilitates the rational scheduling and allocation of resources throughout the workshop. If a certain workstation is overwhelmed with parts, you should increase the number of alternative workstations for that workstation or reduce the processing resources of the previous workstation.

[0051] The method of this invention enables communication between nodes via a Zigbee wireless network. Once the system is deployed, whether it is necessary to increase the number of sensors or the number of machine tools being monitored, only additional router nodes and terminal nodes need to be added to the Zigbee network. Therefore, the operation is simple and the deployment is convenient.

[0052] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A workshop production status acquisition system based on Zigbee wireless communication, characterized in that, include: Several terminal nodes (1), several router nodes (2), coordinator nodes (3), and host computer (4); The coordinator node (3) creates a Zigbee wireless network; Each terminal node (1) collects production status data of equipment in the workshop to form a data packet, and transmits it to the corresponding router node (2) through the Zigbee wireless network. Each router node (2) forwards the received data packets to the coordinator node (3) via the Zigbee wireless network; the router nodes (2) are connected to each other via the Zigbee wireless network; The coordinator node (3) sends the received data packets to the host computer (4). The terminal node (1) includes: The processor, the first infrared diffuse reflection proximity sensor (11), the second infrared diffuse reflection proximity sensor (12), the radio frequency input module, and the clock module; The first infrared diffuse reflection proximity sensor (11) and the second infrared diffuse reflection proximity sensor (12) are arranged along the part transport route; The electrical signal triggered by the first infrared diffuse reflection proximity sensor (11) and the electrical signal triggered by the second infrared diffuse reflection proximity sensor (12) are used to measure the electrical signal of the part. The radio frequency input module collects the ID information of the component and sends it to the processor; The clock module provides real-time clock information to the processor; The processor receives the electrical signal triggered by the first infrared diffuse reflection proximity sensor (11) and the electrical signal triggered by the second infrared diffuse reflection proximity sensor (12) and outputs a component storage signal or a component retrieval signal. The processor uses the storage or retrieval signals of the parts, the ID information of the parts, and the real-time clock information as production status data of the equipment to form a data packet.

2. The system according to claim 1, characterized in that, The power supply method of the terminal node (1) includes: battery power supply or power cord power supply.

3. The system according to claim 1, characterized in that, The infrared diffuse reflection proximity sensor and the processor are connected by wires.

4. The system according to claim 1, characterized in that, The straight-line distance between the terminal node (1) and the router node (2) is less than 10 meters.

5. The system according to claim 1, characterized in that, The terminal node (1) also includes: Key input module and display module; The key input module adjusts and sets the terminal node; The display module is responsible for displaying setting information and production information.

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