A full-automatic hot coil spring production monitoring system

Abstract

The utility model relates to a kind of full-automatic hot coil spring production monitoring system including several monitoring cameras, a signal transmission network and several display terminals, by deploying monitoring camera in multiple key process of production line, real-time distribution is carried out to the display terminal set in different department and place according to production management function with the aid of signal transmission network with field video signal, completely liberate operating personnel from high frequency, long distance field round trip patrol, reduce labor intensity, by the running state of each key process is in the form of video information real-time, synchronously present on the display terminal of central control room, production department and management personnel, realize the centralized and distributed synchronous monitoring of full-line production state, eliminate information blind area and monitoring delay, avoid the production interruption and equipment damage caused by potential problem deterioration such as equipment material shortage, workpiece anomaly or medium leakage, ensure the continuity of production and the reliability of equipment.

Description

Technical Field

[0001] This utility model relates to the field of monitoring and management technology, and in particular to a fully automatic monitoring system for hot-rolled spring production. Background Technology

[0002] In existing technologies, fully automated hot-rolled spring production lines encompass multiple processes, including material preparation, heating and forming, heat treatment, and testing. The production process is lengthy and the equipment is widely distributed. Traditionally, this relies heavily on operators regularly or continuously visiting key equipment locations, such as the material feeding platform of the medium-frequency induction heating furnace, the heat treatment translation mechanism, and the quenching cooling tower outside the workshop, to conduct on-site inspections and visual observations to monitor equipment operation and the production process. This highly manual on-site inspection model not only significantly increases the workload of operators but also, due to the inability to achieve real-time synchronization and sharing of information from multiple points, results in a serious lag in the detection and response to emergencies such as material shortages, abnormal workpiece stacking, or media leaks. If problems are not detected in time during inspection intervals, it will directly lead to production interruptions or equipment damage.

[0003] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model discloses a fully automatic hot-rolled spring production monitoring system. This system solves the problem of the inability to achieve real-time synchronization and sharing of information from multiple points, which leads to a serious lag in the detection and response to emergencies such as material shortages, abnormal workpiece stacking, or media leaks. If problems occur during inspection intervals and are not detected in time, it will directly cause production interruptions or equipment damage.

[0005] The technical solution adopted in this utility model is as follows: A fully automated monitoring system for hot-rolled spring production, characterized in that it includes: A plurality of surveillance cameras are installed at several key process locations on the hot coil spring production line, and the plurality of surveillance cameras are configured to collect on-site video signals. A signal transmission network, which is communicatively connected to a plurality of the surveillance cameras, is used to transmit the on-site video signals; A plurality of display terminals are connected in communication with the signal transmission network, and the plurality of display terminals are configured to receive and display the on-site video signal; the plurality of display terminals are configured in different departments and locations according to production management functions.

[0006] A further technical solution is that the locations of the key processes include at least two of the following: the material feeding platform of the medium-frequency induction heating furnace, the translation mechanism after heat treatment and quenching, and the area below the quenching oil cooling tower.

[0007] A further technical solution is that several key process locations include the medium-frequency induction heating furnace material feeding platform, the translation mechanism after heat treatment and quenching, and the area below the quenching oil cooling tower.

[0008] A further technical solution is that the plurality of surveillance cameras include fixed cameras and pan-tilt cameras.

[0009] A further technical solution is that the signal transmission network is a wired network, a wireless network, or a combination of both.

[0010] A further technical solution is that the plurality of display terminals include a field display screen installed at the head of the spring coiling machine, a monitoring screen in the central control room, a computer monitor in the production and manufacturing department, a computer monitor in the equipment and power department, and a mobile intelligent terminal for leaders of relevant departments.

[0011] A further technical solution is that the fully automatic hot-rolled spring production monitoring system also includes an access control module, which is configured to control the user's access rights to the on-site video signals of different monitoring cameras based on the user's position and function.

[0012] A further technical solution is that the number of monitoring cameras is 23, covering the entire production process from raw material input to finished spring product, as well as the auxiliary equipment area.

[0013] The beneficial effects of this utility model embodiment are as follows: (I) A fully automatic hot-rolled spring production monitoring system includes several monitoring cameras, a signal transmission network, and several display terminals. By deploying monitoring cameras in multiple key processes of the production line and using the signal transmission network to distribute on-site video signals in real time to display terminals set up in different departments and locations according to production management functions, a complete remote visual monitoring system is constructed. This completely liberates operators from high-frequency, long-distance on-site inspections, reducing labor intensity. By presenting the operating status of each key process in the form of video information in real time and synchronously on the display terminals of the central control room, production department, and management personnel, centralized and distributed synchronous monitoring of the entire production line status is realized. This eliminates information blind spots and monitoring delays, avoids production interruptions and equipment damage caused by potential problems such as equipment material shortages, workpiece abnormalities, or media leaks, and ensures the continuity of production and the reliability of equipment.

[0014] (ii) Furthermore, the signal transmission network can be a wired network, a wireless network, or a combination of both. It can flexibly select the most suitable communication method based on the complex equipment layout and building structure of the production site. It leverages the stability and reliability of wired networks to ensure signal transmission quality at key monitoring points, while utilizing the convenient layout of wireless networks to overcome installation difficulties in remote or hard-to-wire areas. This ensures that all on-site video signals collected by monitoring cameras can be transmitted in real-time and completely to display terminals at all levels, providing a fundamental communication guarantee for the stable operation of the entire system.

[0015] (III) Furthermore, the fully automated hot-rolled spring production monitoring system also includes an access control module. This module is configured to control users' access permissions to the on-site video signals of different monitoring cameras based on their positions and functions. By precisely controlling users' access permissions to the video signals of different monitoring cameras according to their positions and functions, the access control module effectively achieves hierarchical management of information security and clear responsibilities. This prevents information chaos or leakage risks caused by unauthorized access and ensures that functional departments such as production, equipment, and safety, as well as their leaders, can only focus on key monitoring screens related to their responsibilities. Thus, while achieving comprehensive monitoring, it constructs a management order with clear responsibilities and efficient collaboration, improving the standardization and security of the entire system management. Attached Figure Description

[0016] Figure 1 This is a schematic block diagram of a fully automatic hot-rolled spring production monitoring system according to this utility model. Detailed Implementation

[0017] To further illustrate the technical means and effects adopted by this utility model in order to achieve the intended utility model purpose, the following detailed description of the specific implementation methods, structure, features and effects of this utility model is provided in conjunction with the accompanying drawings and preferred embodiments.

[0018] First embodiment: A fully automated monitoring system for hot-rolled spring production includes several monitoring cameras, a signal transmission network, and several display terminals. For example, the monitoring cameras include fixed cameras and pan-tilt-zoom (PTZ) cameras.

[0019] Several surveillance cameras are installed at several key process locations on the hot-rolled spring production line, and these cameras are configured to collect on-site video signals. For example, there are 23 surveillance cameras, covering the entire production process from raw material input to finished springs, as well as auxiliary equipment areas. The key process locations include at least two of the following: the medium-frequency induction heating furnace feeding platform, the translation mechanism after heat treatment quenching, and below the quenching oil cooling tower. Specifically, the key process locations include the medium-frequency induction heating furnace feeding platform, the translation mechanism after heat treatment quenching, and below the quenching oil cooling tower.

[0020] The signal transmission network is connected to several surveillance cameras to transmit on-site video signals.

[0021] Several display terminals are communicatively connected to a signal transmission network and are configured to receive and display live video signals. These display terminals are deployed in different departments and locations according to production management functions. For example, the display terminals include a live display screen mounted on the head of a spring coiling machine, a large monitoring screen in the central control room, computer monitors in the production and manufacturing department, computer monitors in the equipment and power department, and mobile smart terminals for relevant department leaders.

[0022] Furthermore, the signal transmission network can be a wired network, a wireless network, or a combination of both. It can flexibly select the most suitable communication method based on the complex equipment layout and building structure of the production site. It leverages the stability and reliability of wired networks to ensure signal transmission quality at key monitoring points, while utilizing the ease of deployment of wireless networks to overcome installation difficulties in remote or hard-to-wire areas. This ensures that all video signals collected by monitoring cameras can be transmitted in real-time and completely to display terminals at all levels, providing a fundamental communication guarantee for the stable operation of the entire system.

[0023] Furthermore, the fully automated hot-rolled spring production monitoring system also includes an access control module. This module is configured to control users' access permissions to the on-site video signals from different monitoring cameras based on their job titles and functions. By precisely controlling users' access permissions to video signals from different monitoring cameras according to their job titles and functions, the access control module effectively achieves hierarchical management of information security and clear responsibilities. This prevents information chaos or leakage risks caused by unauthorized access, and ensures that various functional departments such as production, equipment, and safety, as well as their leaders, can only focus on key monitoring footage relevant to their responsibilities. Thus, while achieving comprehensive monitoring, it also builds a management order with clear responsibilities and efficient collaboration, improving the standardization and security of the entire system management.

[0024] In operation, this embodiment is as follows: First, multiple fixed or pan-tilt-zoom (PTZ) monitoring cameras deployed at key processes in the hot-rolled spring production line, such as the medium-frequency induction heating furnace feeding platform, the heat treatment quenching translation mechanism, and the area beneath the quenching oil cooling tower, continuously collect on-site video signals. These signals are transmitted in real time via wired or wireless signal transmission networks. Subsequently, the transmitted video signals are distributed to various display terminals located in different departments and locations according to production management functions, including the on-site display screen at the head of the spring coiling machine, the monitoring screen in the central control room, the computer monitors in the production and manufacturing department and the equipment and power department, and the mobile smart terminals of relevant leaders. During this process, the access control module strictly controls the access permissions of users to different camera video signals based on their positions and functions. Ultimately, this enables authorized personnel to simultaneously observe the real-time production scenes under their jurisdiction, thereby achieving centralized monitoring and distributed management of the entire production process and enabling immediate detection and response to equipment status, material conditions, and potential risks.

[0025] In this embodiment, a complete remote visual monitoring system was constructed, which completely freed operators from high-frequency, long-distance on-site inspections, reduced labor intensity, and presented the operating status of each key process in real time and synchronously on the display terminals of the central control room, production department and management personnel in the form of video information. This achieved centralized and distributed synchronous monitoring of the entire production line status, eliminated information blind spots and monitoring delays, and avoided production interruptions and equipment damage caused by potential problems such as equipment material shortages, workpiece abnormalities or media leaks, thus ensuring the continuity of production and the reliability of equipment.

[0026] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A fully automated monitoring system for hot-rolled spring production, characterized in that, include: A plurality of surveillance cameras are installed at multiple key process locations on the hot-rolled spring production line, and the plurality of surveillance cameras are configured to collect on-site video signals. A signal transmission network, which is communicatively connected to a plurality of the surveillance cameras, is used to transmit the on-site video signals; A plurality of display terminals are connected in communication with the signal transmission network, and the plurality of display terminals are configured to receive and display the on-site video signal; the plurality of display terminals are configured in different departments and locations according to production management functions.

2. The fully automated hot-rolled spring production monitoring system according to claim 1, characterized in that: The locations of the multiple key processes include at least two of the following: the material feeding platform of the medium-frequency induction heating furnace, the translation mechanism after heat treatment and quenching, and the area below the quenching oil cooling tower.

3. The fully automated hot-rolled spring production monitoring system according to claim 1, characterized in that: The locations of the key processes include the material feeding platform of the medium-frequency induction heating furnace, the translation mechanism after heat treatment and quenching, and the area below the quenching oil cooling tower.

4. The fully automated hot-rolled spring production monitoring system according to claim 1, characterized in that: The multiple surveillance cameras include fixed cameras and pan-tilt cameras.

5. The fully automated hot-rolled spring production monitoring system according to claim 1, characterized in that: The signal transmission network can be a wired network, a wireless network, or a combination of both.

6. The fully automated hot-rolled spring production monitoring system according to claim 1, characterized in that: The multiple display terminals include a field display screen installed at the head of the spring coiling machine, a large monitoring screen in the central control room, a computer monitor in the production and manufacturing department, a computer monitor in the equipment and power department, and mobile smart terminals for leaders of relevant departments.

7. The fully automated hot-rolled spring production monitoring system according to claim 1, characterized in that: The fully automated hot-rolled spring production monitoring system also includes an access control module, which is configured to control the user's access rights to the live video signals from different monitoring cameras based on the user's position and function.

8. The fully automated hot-rolled spring production monitoring system according to claim 1, characterized in that: The number of surveillance cameras is 23, covering the entire production process from raw material input to finished springs, as well as the auxiliary equipment area.

Images