CN115535571A - Intelligent monitoring system and method for conveying equipment - Google Patents
Intelligent monitoring system and method for conveying equipment Download PDFInfo
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- CN115535571A CN115535571A CN202211156367.3A CN202211156367A CN115535571A CN 115535571 A CN115535571 A CN 115535571A CN 202211156367 A CN202211156367 A CN 202211156367A CN 115535571 A CN115535571 A CN 115535571A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/16—Measuring arrangements characterised by the use of optical techniques for measuring the deformation in a solid, e.g. optical strain gauge
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- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
- G01J5/48—Thermography; Techniques using wholly visual means
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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Abstract
The invention provides an intelligent monitoring system and method for conveying equipment, wherein the system comprises: the running state acquisition module is used for acquiring running state data of the conveying driving equipment; the 5G video acquisition module is used for acquiring video information of the conveying equipment; the 5G infrared thermal imaging module is used for acquiring temperature information of conveyed materials in a segmented manner; the line patrol robot module is used for processing the abnormity and feeding back video information according to the instruction of the automatic control module; the main identification controller module is used for identifying video data and thermal imaging data; the automatic control module is used for outputting instructions to the conveying equipment and the inspection robot through an internal algorithm according to the acquired data and the recognition result; the upper computer monitoring module is used for displaying monitoring data, abnormal information, health status, energy consumption and the like of the conveying equipment in real time. Through the scheme, the running state of the conveying equipment can be monitored in real time, abnormal points can be found in time, the abnormality is processed in time, energy loss is reduced, and production safety is guaranteed.
Description
Technical Field
The invention belongs to the technical field of industrial automation, and particularly relates to an intelligent monitoring system and method for conveying equipment.
Background
General production enterprises pay great attention to production safety, production efficiency, energy efficiency and the like, and the operation state and monitoring of production equipment are closely related to production continuity, production saturation, equipment operation efficiency and the like, so that the overall production safety and efficiency of the enterprises can be directly influenced. Material conveying equipment is the key production facility of enterprise, because of power is little, not listed in large-scale key equipment scope, generally many enterprises regularly patrol and examine through basic electrical protection and artifical and supervise, just because monitoring information is incomplete, be difficult to discover equipment hidden danger and the extravagant phenomenon of energy, lead to the trouble discovery untimely with handling, serious hysteresis is more easily to cause secondary failure loss, and simultaneously, conveying equipment operational environment is abominable, also has serious potential safety hazard to the personnel of patrolling and examining.
Disclosure of Invention
In view of this, the embodiment of the invention provides an intelligent monitoring system and an intelligent monitoring method for conveying equipment, which are used for solving the problems that fault finding and processing are not timely due to incomplete detection information of the conveying equipment, the operating environment of the conveying equipment is severe, and serious potential safety hazards exist to inspection personnel.
In a first aspect of the embodiments of the present invention, an intelligent monitoring system for a conveying device is provided, which at least includes a conveying driving device, an operation state acquisition module, a 5G video acquisition module, a 5G infrared thermal imaging module, a main identification controller module, a line inspection robot module, an automation control module, and an upper computer monitoring module;
the running state acquisition module is arranged at a position to be measured of the conveying driving equipment and is used for acquiring running state data of the conveying driving equipment;
the 5G video acquisition module is used for acquiring video information of materials conveyed by the conveying equipment, video information of deformation deflection of the conveying equipment and video information of hidden dangers of tearing and breaking of the conveying equipment and transmitting the acquired video information to the main identification controller module;
the 5G infrared thermal imaging module is used for acquiring temperature information of conveyed materials in a segmented manner and transmitting the thermal imaging temperature information to the main identification controller module;
the inspection robot module is used for receiving an instruction of the automatic control module, positioning an abnormal point through the 5G high-speed camera, processing the abnormality through the manipulator and transmitting video information acquired by the 5G high-speed camera in real time to the main identification controller module;
the main identification controller module is used for identifying material video information of the conveying equipment, deformation deflection of the conveying equipment and tearing and breaking hidden dangers of the conveying equipment;
the automatic control module comprises a speed regulation driving device of the conveying driving device, a master control PLC and a communication unit, wherein the speed regulation driving device is used for driving the conveying device, the master control PLC is used for receiving signals of the running state acquisition module and the master identification controller module and outputting instructions to the conveying driving device and the line patrol robot through an internal logic algorithm, and the communication unit is used for communicating with the line patrol robot module and an upper computer monitoring module;
the upper computer monitoring module is used for displaying running state data of the conveying driving equipment, instructions issued by the automatic control module, video information and abnormal points acquired by the 5G high-speed camera, temperature information and abnormal points of thermal imaging conveying materials, the safety and health state of the conveying equipment, and the energy consumption and the electricity unit consumption of the conveying equipment in real time.
In a second aspect of an embodiment of the present invention, there is provided a method for intelligently monitoring a conveying device, including:
respectively collecting running state data of conveying driving equipment, video information of the conveying equipment and thermal imaging information of the conveying equipment;
identifying material video information of conveying equipment, deformation deflection of the conveying equipment and tearing and breaking hidden dangers of the conveying equipment based on the video data and the thermal imaging data;
when detecting abnormal information of materials on the conveying equipment or the conveying equipment, feeding the abnormal information back to the master control PLC, and outputting a control command to the conveying driving equipment and the line inspection robot by the master control PLC according to the abnormal information;
the inspection robot receives an instruction sent by a master control PLC, positions abnormal points based on a 5G high-speed camera, processes the abnormal points through a manipulator, and collects video information in real time;
the upper computer displays the running state data of the conveying driving equipment, the instruction issued by the master control PLC, the video information and the abnormal points acquired by the 5G high-speed camera, the temperature information and the abnormal points of the thermal imaging conveying material, the safety and health state of the conveying equipment, and the energy consumption and the electricity unit consumption of the conveying equipment in real time.
In the embodiment of the invention, the operation parameters of the conveying equipment, the video and thermal imaging information of the conveying equipment and the conveyed materials are acquired, the identification is carried out through main identification control, and the control is carried out through the automatic controller, so that the monitoring on the state of the conveying equipment, the energy consumption of the equipment and the like can be realized, the abnormity of the conveying equipment or the conveyed materials can be detected in time, the resource waste and the potential safety hazard are avoided, the abnormity is processed through the inspection robot, the equipment safety, the production safety and the safety of inspection personnel can be ensured, the energy utilization rate is effectively improved, and the unnecessary manpower and material resources consumption is reduced.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the embodiments or the prior art descriptions will be briefly described below, and it is obvious that the drawings described below are only some embodiments of the present invention, and those skilled in the art can also obtain other drawings according to the drawings without creative efforts.
Fig. 1 is a schematic structural diagram of an intelligent monitoring system for a conveying apparatus according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating an operation of a main recognition controller module according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of an operating principle of an automation control module according to an embodiment of the present invention;
fig. 4 is a schematic flow chart of an intelligent monitoring method for a conveying apparatus according to an embodiment of the present invention.
Detailed Description
In order to make the objects, features and advantages of the present invention more obvious and understandable, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the embodiments described below are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be understood that the terms "comprises" and "comprising," when used in this specification or claims and in the accompanying drawings, are intended to cover a non-exclusive inclusion, such that a process, method or system, or apparatus that comprises a list of steps or elements is not limited to the listed steps or elements. In addition, "first" and "second" are used to distinguish different objects, and are not used to describe a specific order.
Referring to fig. 1, a system structure schematic diagram of an intelligent monitoring system for a conveying device according to an embodiment of the present invention includes a conveying driving device 110, an operation state acquisition module 120, a 5G video acquisition module 130, a 5G infrared thermal imaging module 140, a line inspection robot module 150, a main identification controller module 160, an automation control module 170, and an upper computer monitoring module 180;
the operation state acquisition module 120 is disposed at a position to be measured of the conveying driving device 110, and is configured to acquire operation state data of the conveying driving device;
in some embodiments, the operation status collection module 120 includes at least a smart meter for collecting three-phase circuits, voltages, powers, and power consumption of the operation of the transmission driving device and a vibration sensor for collecting amplitude and frequency of the operation of the transmission driving device.
The 5G video acquisition module 130 is used for acquiring video information of materials conveyed by conveying equipment, video information of deformation deflection of the conveying equipment and video information of hidden dangers of tearing and breaking of the conveying equipment, and transmitting the acquired video information to the main identification controller module;
the 5G video acquisition module comprises a 5G high-speed camera and is used for acquiring video data of materials on the conveying equipment, deformation deflection, tearing, breaking and the like so as to be identified through the main identification controller module.
The 5G infrared thermal imaging module 140 is used for acquiring temperature information of conveyed materials in a segmented manner and transmitting the thermal imaging temperature information to the main identification controller module;
the 5G infrared thermal imaging module comprises a 5G infrared thermal imaging machine and is used for acquiring temperature information of conveyed materials in a segmented mode so as to be identified through the main identification controller module.
The inspection robot module 150 is used for receiving an instruction of the automation control module, positioning an abnormal point through the 5G high-speed camera, processing the abnormality through the manipulator, and transmitting video information acquired by the 5G high-speed camera in real time to the main identification controller module;
the inspection robot can comprise a 5G high-speed camera, a manipulator and a communication unit, wherein the 5G high-speed camera is used for collecting video information of abnormal points in a short distance, the manipulator is used for processing the abnormality on the conveying equipment, and the communication unit is used for receiving an instruction of the automatic control module and transmitting the collected video information to the main identification controller module.
The main identification controller module 160 is used for identifying material video information of the conveying equipment, deformation deflection of the conveying equipment and tearing and breaking hidden dangers of the conveying equipment;
on the basis of the collected video data and thermal imaging data, the main identification controller can identify the deformation deflection and the like of the conveyed materials and conveying equipment through an AI visual processing technology, and then identify and judge abnormal information.
In some embodiments, the main recognition controller module 160 at least includes an AI intelligent recognition unit and a communication unit, wherein the AI intelligent recognition unit is configured to recognize material video information of the conveying equipment, recognize deformation and deflection of the conveying equipment, and recognize a tearing and breaking hidden danger of the conveying equipment based on video information collected by the 5G high-speed camera; the communication unit is used for communicating with the automation control module and the upper computer monitoring module respectively, transmitting the identified abnormal information to the automation control module and transmitting the video information to the upper computer monitoring module.
The automatic control module 170 comprises a speed regulation driving device of the conveying driving device, a master control PLC and a communication unit, wherein the speed regulation driving device is used for driving the conveying device, the master control PLC is used for receiving signals of the running state acquisition module and the master identification controller module, outputting instructions to the conveying driving device and the line patrol robot through an internal logic algorithm, and the communication unit is used for communicating with the line patrol robot module and an upper computer monitoring module;
the speed regulation driving device can drive the conveying driving device 110 to change the running state, a master control PLC (Programmable Logic Controller) can send control instructions to the conveying driving device and the line patrol robot to execute corresponding operations, and the communication unit integrates multiple protocols such as Modbus-RTU, modbus-TCP, TCP/IP and 5G and is used for communicating with the line patrol robot and an upper computer monitoring module.
The upper computer monitoring module 180 is used for displaying running state data of the conveying driving device, instructions issued by the automatic control module, video information and abnormal points acquired by the 5G high-speed camera, temperature information and abnormal points of thermal imaging conveying materials, the safety and health state of the conveying device, and the energy consumption and the electricity unit consumption of the conveying device in real time.
In some embodiments, the upper computer monitoring module 180 at least includes a real-time monitoring unit for the running state of the conveying equipment, a video monitoring unit for the conveying equipment, a thermal imaging monitoring unit for the temperature of the conveying equipment, a diagnostic unit for the conveying equipment, and an energy-saving analysis unit for the conveying equipment;
the real-time monitoring unit of the running state of the conveying equipment is used for displaying the running three-phase current, the line voltage, the active power, the current-day accumulated power consumption and the current-month accumulated power consumption of the conveying equipment in real time, and issuing start and stop and speed instructions to the speed regulation driving equipment and action instructions of the inspection robot;
the conveying equipment video monitoring unit is used for displaying video information acquired by each segmented 5G height camera and the inspection robot and intelligently marking abnormal points;
the conveying equipment temperature thermal imaging monitoring unit is used for displaying temperature information of conveyed materials in an image form and intelligently marking abnormal points;
the conveying equipment diagnosis unit is used for comprehensively diagnosing and analyzing the safe and healthy state of the conveying equipment based on the identified material color shape, the deformation and deflection of the conveying equipment, the tearing and breaking hidden danger of the conveying equipment, thermal imaging and the running state information of the conveying driving equipment, recording abnormal data and images every time, forming a safety and health diagnosis daily report and a monthly report, and performing multi-dimensional statistical analysis at least by combining the abnormal type, the occurrence time, the abnormal times and the duration;
the energy-saving analysis unit of the conveying equipment is used for analyzing the energy consumption and the electricity consumption of the conveying equipment, automatically screening and extracting comparable conditions through a built-in algorithm, comparing energy efficiency differences and outputting an energy efficiency analysis report.
As shown in fig. 1, the operation state acquisition module 120 is disposed at a position to be measured of the conveying driving device 110, and is connected to the conveying driving device 110 through a signal line, and the operation state acquisition module 120 communicates with the master control PLC through RS 485;
the 5G video acquisition module 130 is arranged in a conveying equipment area and transmits video signals to the main identification controller module 160 through 5G communication;
the 5G infrared thermal imaging module 140 is arranged in a conveying equipment area, and transmits thermal imaging data to the main identification controller module 160 through 5G communication;
the line patrol robot module 150 is arranged in a conveying equipment area, receives an instruction of the automation control module 170 through 5G communication, and sends a collected video signal to the main identification controller 160;
the main identification controller module 160 is arranged in a main control room and is respectively connected with the automation control module 170 and the upper computer monitoring module 180 through communication cables;
the automation control module 170 is arranged in a main controller room, receives a signal of the main identification controller module 160 through a communication cable, and receives an instruction sent by the upper computer monitoring module 180 to control the transmission driving device 110 and the inspection robot module 150;
the upper computer monitoring module 180 is connected with the automation control module 170, the main identification controller 160 and the line patrol robot module 150 through communication cables, and is based on TCP/IP protocol communication.
Preferably, in the main identification controller module, the identification of the video information of the material of the conveying equipment, the deformation and deflection of the conveying equipment, and the tearing and breaking hidden danger of the conveying equipment comprises:
generating a main identification knowledge base through built-in AI and VI algorithms based on the collected video data and thermal imaging data, and continuously correcting the knowledge base;
automatically and intelligently identifying the color, the granularity, the temperature and the deformation deflection of the conveying equipment of the material conveyed on the conveying equipment through AI and VI algorithms for the video information to be identified and the thermal imaging data;
automatically comparing the identified material color, granularity, temperature and deformation deflection with a main identification knowledge base through distance anomaly detection of an LOF anomaly detection algorithm, intelligently judging local anomaly factors in the material color, granularity, temperature and deformation deflection data, and positioning an anomaly position to obtain determined anomaly information;
automatically comparing uncertain abnormal information with a main identification knowledge base through a membership function method of an FLC fuzzy logic control algorithm, and intelligently marking abnormal positions;
and feeding back the abnormal information to the automatic control module.
For example, as shown in fig. 2, the collected video information and thermal imaging information are input to a central processing unit, a main identification knowledge base is generated through built-in AI and VI algorithms, and the knowledge base is automatically and intelligently corrected during long-term operation; automatically and intelligently identifying the color, granularity and temperature of the materials conveyed on the conveying equipment and the deformation deflection of the conveying equipment through built-in AI and VI algorithms; automatically comparing the distance anomaly detection method with a main identification knowledge base through an LOF anomaly detection algorithm, intelligently identifying local anomaly factors of color, granularity, temperature and deformation deflection data, intelligently positioning an anomaly position, and feeding determined information back to a central controller; automatically comparing uncertain abnormal information with a main identification knowledge base through a membership function method of an FLC fuzzy logic control algorithm, intelligently marking abnormal positions, and feeding back the information to a central controller; the central controller automatically selects a processing scheme according to the level of the abnormality and feeds back the processing scheme to the automatic controller, the high-level abnormality outputs an emergency stop instruction, the middle-level abnormality outputs a speed reduction operation instruction, and the low-level abnormality sends an abnormality signal.
The central processing unit is a processor of a main identification Controller module, the LOF (Local outer factor) anomaly detection algorithm judges whether each point p is an anomaly point by comparing the density of the point with the density of the neighborhood point, and the FLC (Fuzzy Logic Controller) Fuzzy Logic control algorithm is an algorithm which expresses process variables into program language variables with limited values and processes the program language variables by a series of condition rules.
Further, the master control PLC receives the abnormal information fed back by the main identification controller module and executes a corresponding control strategy according to the abnormal level;
if the first level is abnormal, an emergency stop instruction is sent to the speed regulation driving device and a warning signal is sent to the upper computer monitoring module, if the second level is abnormal, a speed reduction operation instruction is sent to the speed regulation driving device and a warning signal is sent to the upper computer monitoring module, and if the third level is abnormal, a warning signal is sent to the upper computer monitoring module.
The first level exception may correspond to a high level exception, the second level exception may correspond to a medium level exception, and the third level exception may correspond to a low level exception.
Preferably, as shown in fig. 3, after the automatic control module issues an exception handling instruction, each module unit executes a corresponding control policy according to an exception level:
after receiving the instruction of the master control PLC, the speed regulation driving equipment automatically outputs a control signal to drive the conveying equipment to change the running state;
after receiving the abnormity warning signal, the upper computer monitoring module sends an instruction to the master control PLC to drive the inspection robot to process abnormity;
after receiving the instruction of the master control PLC, the inspection robot automatically positions an abnormal point through the 5G high-speed camera, drives the robot hand to handle the abnormality and transmits a video signal acquired by the 5G high-speed camera to the main identification controller, and the main identification controller transmits a real-time acquired frequency signal to the upper computer monitoring module;
the upper computer monitoring module monitors the processing operation of the inspection robot in real time, and sends an instruction to a main control PLC of the automatic control module in the upper computer monitoring module so as to finely adjust the action of the manipulator through manual operation.
In this embodiment, not only can monitor conveying equipment, transported substance material etc. and acquire data such as equipment running state, energy consumption in real time, can discover in time that equipment is unusual moreover, can accurately detect through corresponding logical algorithm and judge abnormal point, conveniently in time handle unusually through patrolling and examining the robot to can reduce consuming of the energy, guarantee conveying equipment safety and production safety.
Fig. 4 is a schematic flow chart of an intelligent monitoring method for a conveying apparatus according to an embodiment of the present invention, where the method includes:
s401, respectively collecting running state data of conveying driving equipment, video information of the conveying equipment and thermal imaging information of the conveying equipment;
the intelligent ammeter is used for detecting three-phase current, voltage, power and electricity consumption quantity of the operation of the conveying driving equipment, and the vibration sensor is used for detecting the amplitude and frequency of the operation of the conveying driving equipment.
The video information of the materials conveyed by the conveying equipment, the video information of the deformation and deflection of the conveying equipment and the video information of the hidden danger of tearing and breaking of the conveying equipment are collected by a 5G high-speed camera.
The temperature information of the conveyed materials is collected in a segmented mode through a 5G infrared thermal imaging machine.
S402, identifying material video information of conveying equipment, deformation deflection of the conveying equipment and tearing and breaking hidden dangers of the conveying equipment based on the video data and the thermal imaging data;
the material video information on the conveying equipment, the deformation deflection of the conveying equipment and the tearing and breaking hidden danger of the conveying equipment are intelligently identified through AI.
S403, when abnormal information of the materials on the conveying equipment or the conveying equipment is detected, feeding the abnormal information back to the master control PLC, and outputting a control instruction to the conveying driving equipment and the line inspection robot by the master control PLC according to the abnormal information;
specifically, the detecting of the abnormal information of the material on the conveying equipment or the conveying equipment includes:
generating a main identification knowledge base through built-in AI and VI algorithms based on the collected video data and thermal imaging data, and continuously correcting the knowledge base;
automatically and intelligently identifying the color, the granularity, the temperature and the deformation deflection of the conveying equipment of the material conveyed on the conveying equipment through AI and VI algorithms for the video information to be identified and the thermal imaging data;
automatically comparing the identified material color, granularity, temperature and deformation deflection with a main identification knowledge base through distance anomaly detection of an LOF anomaly detection algorithm, intelligently judging local anomaly factors in the material color, granularity, temperature and deformation deflection data, and positioning an anomaly position to obtain determined anomaly information;
automatically comparing uncertain abnormal information with a main identification knowledge base through a membership function method of an FLC fuzzy logic control algorithm, and intelligently marking abnormal positions;
and feeding back the abnormal information to the master control PLC.
Further, the master control PLC receives the abnormal information fed back by the main identification controller module and executes a corresponding control strategy according to the abnormal level;
if the first level is abnormal, an emergency stop instruction is sent to the speed regulation driving device and a warning signal is sent to the upper computer monitoring module, if the second level is abnormal, a speed reduction operation instruction is sent to the speed regulation driving device and a warning signal is sent to the upper computer monitoring module, and if the third level is abnormal, a warning signal is sent to the upper computer monitoring module.
Preferably, after receiving the instruction of the master control PLC, the speed regulation driving equipment automatically outputs a control signal to drive the conveying equipment to change the running state;
after receiving the abnormity warning signal, the upper computer monitoring module sends an instruction to the master control PLC to drive the inspection robot to process abnormity; and after receiving the instruction of the master control PLC, the inspection robot performs exception handling.
S404, the inspection robot receives an instruction sent by a master control PLC, positions an abnormal point based on a 5G high-speed camera, processes the abnormality through a manipulator, and collects video information in real time;
specifically, after receiving the abnormity warning signal, the upper computer monitoring module sends an instruction to the master control PLC to drive the inspection robot to process abnormity;
after receiving the instruction of the master control PLC, the inspection robot automatically positions abnormal points through the 5G high-speed camera, drives the robot hand to handle the abnormality, and transmits video signals acquired by the 5G high-speed camera to the master identification controller, and the master identification controller transmits real-time acquired frequency signals to the upper computer monitoring module;
the upper computer monitoring module monitors the processing operation of the inspection robot in real time, and sends an instruction to a main control PLC of the automatic control module in the upper computer monitoring module so as to finely adjust the action of the manipulator through manual operation.
S405, the upper computer displays the running state data of the conveying driving device, the instruction issued by the master control PLC, the video information and the abnormal point collected by the 5G high-speed camera, the temperature information and the abnormal point of the thermal imaging conveying material, the safe and healthy state of the conveying device, and the energy consumption and the electricity unit consumption of the conveying device in real time.
Specifically, the upper computer at least comprises a conveying equipment running state real-time monitoring unit, a conveying equipment video monitoring unit, a conveying equipment temperature thermal imaging monitoring unit, a conveying equipment diagnosis unit and a conveying equipment energy-saving analysis unit;
the real-time monitoring unit of the running state of the conveying equipment is used for displaying the running three-phase current, the line voltage, the active power, the current-day accumulated power consumption and the current-month accumulated power consumption of the conveying equipment in real time, and issuing start and stop and speed instructions to the speed regulation driving equipment and action instructions of the inspection robot;
the conveying equipment video monitoring unit is used for displaying video information acquired by each segmented 5G height camera and the inspection robot and intelligently marking abnormal points;
the conveying equipment temperature thermal imaging monitoring unit is used for displaying temperature information of conveyed materials in an image form and intelligently marking abnormal points;
the conveying equipment diagnosis unit is used for comprehensively diagnosing and analyzing the safe and healthy state of the conveying equipment based on the identified material color shape, the deformation and deflection of the conveying equipment, the tearing and breaking hidden danger of the conveying equipment, thermal imaging and the running state information of the conveying driving equipment, recording abnormal data and images every time, forming a safety and health diagnosis daily report and a monthly report, and performing multi-dimensional statistical analysis at least by combining the abnormal type, the occurrence time, the abnormal times and the duration;
the energy-saving analysis unit of the conveying equipment is used for analyzing the energy consumption and the unit power consumption of the conveying equipment, automatically screening and extracting comparable conditions through a built-in algorithm, comparing energy efficiency differences and outputting an energy efficiency analysis report.
It should be understood that, the sequence numbers of the steps in the foregoing embodiments do not imply an execution sequence, and the execution sequence of each process should be determined by its function and inherent logic, and should not constitute any limitation to the implementation process of the embodiments of the present invention.
It can be clearly understood by those skilled in the art that, for convenience and brevity of description, the specific working processes of the above-described methods and steps may refer to the corresponding functional modules in the foregoing system embodiments, and are not described herein again.
In the above embodiments, the description of each embodiment has its own emphasis, and reference may be made to the related description of other embodiments for parts that are not described or recited in any embodiment.
The above-mentioned embodiments are only used for illustrating the technical solutions of the present invention, and not for limiting the same; although the present invention has been described in detail with reference to the foregoing embodiments, it should be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Claims (9)
1. An intelligent monitoring system of conveying equipment is characterized by at least comprising conveying driving equipment, an operating state acquisition module, a 5G video acquisition module, a 5G infrared thermal imaging module, a main identification controller module, a line inspection robot module, an automatic control module and an upper computer monitoring module;
the running state acquisition module is arranged at a position to be measured of the conveying driving equipment and is used for acquiring running state data of the conveying driving equipment;
the 5G video acquisition module is used for acquiring video information of materials conveyed by the conveying equipment, video information of deformation deflection of the conveying equipment and video information of hidden dangers of tearing and breaking of the conveying equipment and transmitting the acquired video information to the main identification controller module;
the 5G infrared thermal imaging module is used for acquiring temperature information of conveyed materials in a segmented manner and transmitting the thermal imaging temperature information to the main identification controller module;
the inspection robot module is used for receiving an instruction of the automatic control module, positioning an abnormal point through the 5G high-speed camera, processing the abnormality through the manipulator and transmitting video information acquired by the 5G high-speed camera in real time to the main identification controller module;
the main identification controller module is used for identifying material video information of the conveying equipment, deformation deflection of the conveying equipment and tearing and breaking hidden dangers of the conveying equipment;
the automatic control module comprises a speed regulation driving device of the conveying driving device, a master control PLC and a communication unit, the speed regulation driving device is used for driving the conveying device, the master control PLC is used for receiving signals of the running state acquisition module and the master identification controller module and outputting instructions to the conveying driving device and the line patrol robot through an internal logic algorithm, and the communication unit is used for communicating with the line patrol robot module and the upper computer monitoring module;
the upper computer monitoring module is used for displaying running state data of the conveying driving equipment, instructions issued by the automatic control module, video information and abnormal points acquired by the 5G high-speed camera, temperature information and abnormal points of thermal imaging conveying materials, the safe and healthy state of the conveying equipment, and the energy consumption and the electricity unit consumption of the conveying equipment in real time.
2. The system of claim 1, wherein the operation state acquisition module is arranged at a position to be measured of the conveying driving device and is connected with the conveying driving device through a signal line, and the operation state acquisition module is communicated with the master control PLC through RS 485;
the 5G video acquisition module is arranged in a conveying equipment area and transmits video signals to the main identification controller module through 5G communication;
the 5G infrared thermal imaging module is arranged in the conveying equipment area and transmits thermal imaging data to the main identification controller module through 5G communication;
the main identification controller module is arranged in a main control room and is respectively connected with the automation control module and the upper computer monitoring module through communication cables;
the line patrol robot module is arranged in a conveying equipment area, receives an instruction of the automatic control module through 5G communication, and sends a collected video signal to the main identification controller;
the automatic control module is arranged in the main controller room, receives a signal of the main identification controller module through a communication cable, and receives an instruction sent by the upper computer monitoring module so as to control the transmission driving device and the line patrol robot module;
the upper computer monitoring module is respectively connected with the automation control module, the main identification controller and the line inspection robot module through communication cables and is communicated based on a TCP/IP protocol.
3. The system of claim 1, wherein the operation state acquisition module at least comprises a smart electric meter and a vibration sensor, the smart electric meter is used for acquiring a three-phase circuit, voltage, power and electricity consumption of the operation of the conveying driving device, and the vibration sensor is used for acquiring the amplitude and frequency of the operation of the conveying driving device.
4. The system of claim 1, wherein the main identification controller module at least comprises an AI intelligent identification unit and a communication unit, wherein the AI intelligent identification unit is used for identifying material video information of the conveying equipment, identifying deformation and deflection of the conveying equipment and hidden danger of tearing and breaking of the conveying equipment based on video information collected by a 5G high-speed camera;
the communication unit is used for communicating with the automation control module and the upper computer monitoring module respectively, transmitting the identified abnormal information to the automation control module and transmitting the video information to the upper computer monitoring module.
5. The system according to claim 1, wherein the upper computer monitoring module at least comprises a conveying equipment running state real-time monitoring unit, a conveying equipment video monitoring unit, a conveying equipment temperature thermal imaging monitoring unit, a conveying equipment diagnosis unit and a conveying equipment energy-saving analysis unit;
the real-time monitoring unit for the running state of the conveying equipment is used for displaying running three-phase current, line voltage, active power, current consumption accumulated on the day, current consumption accumulated on the month, start and stop and speed instructions sent to the speed-regulating driving equipment and action instructions of the inspection robot in real time;
the conveying equipment video monitoring unit is used for displaying video information acquired by each segmented 5G height camera and the inspection robot and intelligently marking abnormal points;
the conveying equipment temperature thermal imaging monitoring unit is used for displaying temperature information of conveyed materials in an image form and intelligently marking abnormal points;
the conveying equipment diagnosis unit is used for comprehensively diagnosing and analyzing the safe and healthy state of the conveying equipment based on the identified material color shape, the deformation and deflection of the conveying equipment, the tearing and breaking hidden danger of the conveying equipment, thermal imaging and the running state information of the conveying driving equipment, recording abnormal data and images every time, forming a safety and health diagnosis daily report and a monthly report, and performing multi-dimensional statistical analysis at least by combining the abnormal type, the occurrence time, the abnormal times and the duration;
the energy-saving analysis unit of the conveying equipment is used for analyzing the energy consumption and the electricity consumption of the conveying equipment, automatically screening and extracting comparable conditions through a built-in algorithm, comparing energy efficiency differences and outputting an energy efficiency analysis report.
6. The system of claim 1, wherein the identifying video information of the material of the conveying equipment, the deformation flexibility of the conveying equipment, and the tearing and breaking hidden danger of the conveying equipment comprises:
generating a main identification knowledge base through built-in AI and VI algorithms based on the collected video data and thermal imaging data, and continuously correcting the knowledge base;
automatically and intelligently identifying the color, the granularity, the temperature and the deformation deflection of the conveying equipment of the material conveyed on the conveying equipment through AI and VI algorithms for the video information to be identified and the thermal imaging data;
automatically comparing the identified material color, granularity, temperature and deformation deflection with a main identification knowledge base through distance anomaly detection of an LOF anomaly detection algorithm, intelligently judging local anomaly factors in the material color, granularity, temperature and deformation deflection data, and positioning an anomaly position to obtain determined anomaly information;
automatically comparing uncertain abnormal information with a main identification knowledge base by a membership function method of an FLC fuzzy logic control algorithm, and intelligently marking abnormal positions;
and feeding back the abnormal information to the automatic control module.
7. The system of claim 6, wherein the automation control module comprises:
the master control PLC receives the abnormal information fed back by the master identification controller module and executes a corresponding control strategy according to the abnormal level;
if the first level is abnormal, an emergency stop instruction is sent to the speed regulation driving device and a warning signal is sent to the upper computer monitoring module, if the second level is abnormal, a speed reduction operation instruction is sent to the speed regulation driving device and a warning signal is sent to the upper computer monitoring module, and if the third level is abnormal, a warning signal is sent to the upper computer monitoring module.
8. The system of claim 7, wherein the master PLC receives the exception information fed back by the master recognition controller module, and executing the corresponding control strategy according to the exception level comprises:
after receiving the instruction of the master control PLC, the speed regulation driving equipment automatically outputs a control signal to drive the conveying equipment to change the running state;
after receiving the abnormity warning signal, the upper computer monitoring module sends an instruction to the master control PLC to drive the inspection robot to process abnormity;
after receiving the instruction of the master control PLC, the inspection robot automatically positions abnormal points through the 5G high-speed camera, drives the robot hand to handle the abnormality, and transmits video signals acquired by the 5G high-speed camera to the main identification controller module, and the main identification controller module transmits real-time acquired frequency signals to the upper computer monitoring module;
the upper computer monitoring module monitors the processing operation of the inspection robot in real time, and sends an instruction to a main control PLC of the automatic control module in the upper computer monitoring module so as to finely adjust the action of the manipulator through manual operation.
9. An intelligent monitoring method for conveying equipment is characterized by comprising the following steps:
respectively acquiring running state data of the conveying driving equipment, video information of the conveying equipment and thermal imaging information of the conveying equipment;
identifying material video information of conveying equipment, deformation deflection of the conveying equipment and tearing and breaking hidden dangers of the conveying equipment based on the video data and the thermal imaging data;
when detecting abnormal information of materials on the conveying equipment or the conveying equipment, feeding the abnormal information back to the master control PLC, and outputting a control instruction to the conveying driving equipment and the line patrol robot by the master control PLC according to the abnormal information;
the inspection robot receives an instruction sent by a master control PLC, positions abnormal points based on a 5G high-speed camera, processes the abnormality through a manipulator, and collects video information in real time;
the upper computer displays the running state data of the conveying driving equipment, the instruction issued by the master control PLC, the video information and the abnormal points acquired by the 5G high-speed camera, the temperature information and the abnormal points of thermal imaging conveying materials, the safe and healthy state of the conveying equipment, and the energy consumption and the electricity unit consumption of the conveying equipment in real time.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202211156367.3A CN115535571A (en) | 2022-09-21 | 2022-09-21 | Intelligent monitoring system and method for conveying equipment |
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| CN202211156367.3A CN115535571A (en) | 2022-09-21 | 2022-09-21 | Intelligent monitoring system and method for conveying equipment |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117465950A (en) * | 2023-12-26 | 2024-01-30 | 常州佰承复合材料有限公司 | Nonstandard automation equipment conveying device |
| CN117870779A (en) * | 2024-03-12 | 2024-04-12 | 深圳市广正弘自动化科技有限公司 | Remote wireless intelligent monitoring method and system for automation equipment |
| CN117870779B (en) * | 2024-03-12 | 2024-05-31 | 深圳市广正弘自动化科技有限公司 | Remote wireless intelligent monitoring method and system for automation equipment |
-
2022
- 2022-09-21 CN CN202211156367.3A patent/CN115535571A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117465950A (en) * | 2023-12-26 | 2024-01-30 | 常州佰承复合材料有限公司 | Nonstandard automation equipment conveying device |
| CN117465950B (en) * | 2023-12-26 | 2024-04-05 | 常州佰承复合材料有限公司 | Nonstandard automation equipment conveying device |
| CN117870779A (en) * | 2024-03-12 | 2024-04-12 | 深圳市广正弘自动化科技有限公司 | Remote wireless intelligent monitoring method and system for automation equipment |
| CN117870779B (en) * | 2024-03-12 | 2024-05-31 | 深圳市广正弘自动化科技有限公司 | Remote wireless intelligent monitoring method and system for automation equipment |
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