Manufacturing an automatic reading module for analog measuring devices with the ability to wirelessly transmit information to a central processing system

Abstract

This invention relates to the design and manufacture of an intelligent module for automatic and remote reading of analog measuring devices such as gas, water, electricity meters, and various types of industrial manometers and pressure gauges. This module, without the need to replace or change the structure of the main device, uses an embedded imaging unit to record the image of the device's analog screen and sends it to the central information processing system via wireless communication.\n\nThe central system, using image processing algorithms, extracts numerical values ​​from the sent images and provides the results to the user in a web-based management panel.\n\nThe designed module has the ability to be powered by two different energy sources:\n 1. City electricity via adapter\n 2. Independent solar system including solar panel and internal battery\n\nThis flexibility in power supply allows the module to be used in various environmental conditions and places where there is no access to city electricity.\n\nIt is worth noting that the initial design, development and testing of this module was carried out on domestic and industrial gas meters; however, its architecture and operation are such that it can be generalized to other analog measuring equipment such as water meters, electricity meters, industrial pressure gauges and other similar equipment.\n\nThis module also has the ability to be expanded to remotely control peripheral equipment such as electric valves for cutting and connecting the current flowing through measuring devices (such as gas meters). In this way, through the digital pins of the processor board, the current control relays can be activated to enable the possibility of cutting or connecting the current in a safe and remotely controlled manner. This capability, especially in emergency situations or in centralized management, can play an effective role in increasing safety and optimizing consumption.lh.

Description

Description of the invention Title of the invention Building an automatic reading module for analog measuring devices with the ability to wirelessly transmit information to a central processing system Technical background of the relevant invention This invention falls into the field of intelligent reading tools for analog measuring devices such as gas, water, and electricity meters, and industrial equipment such as manometers and pressure gauges. Technical problem and stating the objectives of the invention In many industries and domestic applications, information about resource consumption (gas, water, electricity) is recorded by analog meters. This traditional method requires the physical presence of human resources and manual readings, which can lead to errors, delays, high costs and even corruption. Also, in many industrial facilities or inaccessible areas, access to meters is difficult and expensive. The purpose of this invention is to design and implement an automatic and remote reading system for analog meters without the need to modify or replace existing meters. This module performs the reading process intelligently by capturing an image of the meter screen and sending it to the central system. It also has the ability to be expanded to control consumption flow (for example, turning gas on and off) remotely. A description of the state of the prior art and the history of developments related to the claimed invention. In the global market, projects have been introduced to convert analog meters to digital, but they often require a complete replacement of the meter or the use of precise mechanical sensors on the indicators. For example, in patent number CN111760922A, an image processing system for an electricity meter is introduced that is installed only on a specific model of meter. Or in patent WO2019158391A1, there is a need to install an internal optical sensor inside the meter. In none of these cases has a system been introduced that: No need to open or change the meter structure, By installing only one external module, Take a full screenshot of the page, And send data for processing by wireless transmission. The present invention offers a new innovation by combining a camera module, flexible power supply capability, and wireless transmission, independently and installable on any type of analog meter. Providing a solution to an existing technical problem along with an accurate, sufficient, and integrated description of the invention The invented module consists of the following parts: 1. Imaging unit (camera): The camera module (such as ESP32-CAM) is installed on the meter and records the image of the analog screen at specific time intervals. 2. Central processor: The module has a built-in processor to control image timing, compression, and data transmission. 3. Wireless communication unit: Sends images via Wi-Fi, GSM or NB-IoT network to the central server. 4.Combined power supply: oMains electricity (via adapter) oOr independent power supply with solar panel and internal rechargeable battery 5. Possibility of controlling peripheral equipment (such as solenoid valves) remotely, through the module's digital output to cut or connect the current flow. 6. Central system (server) includes: oReceiving images oImage analysis with OCR algorithm and image processing oConfirming the extracted information in the database oDisplay information in the web-based management panel The important point is that all of the above steps are performed without the need for human intervention on site. The main problem that this invention intends to solve is the lack of a solution for automatic and non-contact reading of information from meters and analog measuring devices without the need to change their physical structure. In most existing systems, there is either a need to replace the meter and measuring devices or it requires the installation of internal equipment and intervention in their structure, which is costly and limited to specific models. The present invention provides an integrated system that includes an imaging module, a central processor, a wireless communication module, an independent power supply and central analysis software. This module records images of the meter screen at specific time intervals without interfering with the internal structure of the meter and only by installing it on the outside. Explanation of shapes, maps and diagrams 1- Solar panel The photovoltaic panel is responsible for providing electrical energy to the system. This panel uses sunlight to generate direct current (DC), allowing the module to operate independently without the need for an external power source. 2- Charging module This section is responsible for managing the current and voltage input from the solar panel to the battery. The charging module uses charge control and protection circuits to prevent damage to the battery due to overcharging or deep discharge. 3- Lithium battery The lithium-ion or lithium-polymer battery acts as an energy storage source and provides electrical power to power the processor, camera, and communication modules when there is no sunlight. 4- Central processor (ESP32) A microcontroller board equipped with an image processing unit and wireless communication capabilities. This unit is responsible for controlling the camera, managing relays, sending images to the server, and receiving remote commands. 5- Adjustable camera A digital camera with variable angle and focus for precise imaging of the meter display. The camera sends high-quality images to the processor for processing and transmission. 6- Gas meter with control relay Example of a measuring device on which the module is installed. The relay built into the meter can perform the task of turning on and off the solenoid valve or peripheral equipment based on commands received from the server. 7-8-9- Multipurpose control relays Three independent relays that can control peripherals such as solenoid valves, alarms, or other control systems. These relays are activated or deactivated by the central processor. 10- WiFi module A wireless communication unit that can connect to the Internet or Intranet networks. In addition to sending and receiving data, this module has the ability to create an access point for direct communication with other modules. 11- SIM card module (GSM / 4G) If there is no access to a Wi-Fi network, this module establishes a cellular connection and allows images to be sent and commands to be received via the mobile network. 12- Central server A system for receiving images from the module, storing them in a database, and sending control commands to the processor. This server also provides a user interface for the operator or the consumption management system. 13- Image processing unit A server or cloud computing system that analyzes received images using image processing and OCR algorithms, extracts consumption figures, and sends the results to the main server. A clear and precise statement of the advantages of the claimed invention over prior inventions.  Simple installation without changing the meter structure  Independent of the meter brand and model  Powered by city electricity or solar panels  Possibility of remote processing without human intervention  Possibility to add flow control (solenoid valve) without additional wiring  Reduce maintenance costs, human error, and improve safety in industrial conditions Description of at least one implementation method for implementing the invention  The module is installed on the meter panel and takes images periodically.  The image is sent to the server.  The server processes the data and extracts the reading number.  Information is displayed on the web panel  If necessary, the user can remotely command the solenoid valve to be turned on or off. Explicit mention of the industrial application of the invention Municipal gas, water and electricity distribution companies Industrial installations for monitoring pressure equipment, manometers, etc. Large residential or office complexes for smart monitoring Oil, petrochemical and power plants industries Crisis management and safety for quick power outages in emergencies

Claims

Claim 1 (Independent - Method) A method for automatic and non-contact reading of information from analog measuring devices without the need to change their physical structure, which includes the following steps: a) installing an imaging module on the exterior of the analog measuring device; b) adjusting imaging parameters including at least one of light, contrast, transparency, magnification, and imaging area, in accordance with the lighting conditions and imaging of the measuring device screen; c) recording an image from the measuring device screen at specified time intervals; d) performing pre-processing of the image recorded in the imaging module and before sending the data to the central processing system, including at least one of the steps of selecting the information area, correcting geometric and angular distortions of the image, and improving the image quality; e) sending the data obtained from step (d) to the central processing system via a wireless communication platform; f) analyzing the data received in the central processing system and extracting consumption information; In a way that the implementation of the above steps is carried out without human intervention and without making any changes to the internal structure of the measuring device, leading to a reduction in reading errors caused by changes.Mounting angle, varying lighting conditions, and contamination of the device's display surface are measured. Claim 2 (dependent) The method according to claim 1, wherein the image capture is performed adaptively and in accordance with the power supply status and communication conditions of the module. Claim 3 (dependent) The method according to claim 1, wherein the image preprocessing includes adjusting brightness and contrast to increase the accuracy of information extraction in adverse environmental conditions.