AU2020204595B2 - Wireless monitoring and control system applied in factory - Google Patents

Wireless monitoring and control system applied in factory Download PDF

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Publication number
AU2020204595B2
AU2020204595B2 AU2020204595A AU2020204595A AU2020204595B2 AU 2020204595 B2 AU2020204595 B2 AU 2020204595B2 AU 2020204595 A AU2020204595 A AU 2020204595A AU 2020204595 A AU2020204595 A AU 2020204595A AU 2020204595 B2 AU2020204595 B2 AU 2020204595B2
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wireless
electricity consumption
power supply
plc
control center
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AU2020204595A
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AU2020204595A1 (en
Inventor
Xinhui Du
Ze Wang
Qing Xue
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Taiyuan University of Technology
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Taiyuan University of Technology
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • 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
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R22/00—Arrangements for measuring time integral of electric power or current, e.g. electricity meters
    • G—PHYSICS
    • G08—SIGNALLING
    • G08C—TRANSMISSION SYSTEMS FOR MEASURED VALUES, CONTROL OR SIMILAR SIGNALS
    • G08C17/00—Arrangements for transmitting signals characterised by the use of a wireless electrical link
    • G08C17/02—Arrangements for transmitting signals characterised by the use of a wireless electrical link using a radio link
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02D—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN INFORMATION AND COMMUNICATION TECHNOLOGIES [ICT], I.E. INFORMATION AND COMMUNICATION TECHNOLOGIES AIMING AT THE REDUCTION OF THEIR OWN ENERGY USE
    • Y02D30/00—Reducing energy consumption in communication networks
    • Y02D30/70—Reducing energy consumption in communication networks in wireless communication networks
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Power Engineering (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • Automation & Control Theory (AREA)
  • Remote Monitoring And Control Of Power-Distribution Networks (AREA)

Abstract

The present invention discloses a wireless monitoring and control system applied in a factory. A wireless electricity consumption sensor monitors electrical parameters in real time and wirelessly sends the electrical parameters to a control center; the control center processes the parameters and sends a control command to a PLC; and the PLC receives the command and controls the switching of a standby power supply. A visual operation interface available on a PC and a mobile phone is designed. Real-time on-line data monitoring can be implemented by using the wireless electricity consumption sensor. Medium and short distance wireless control can be implemented by using the PLC equipped with a communication module. A photovoltaic power generation system, as a standby power supply and a new energy power supply tending to mature, can save energy while achieving a power supply function. Components used in the present invention pertain to wireless hardware for wireless information transmission in a factory, and have a small size, which reduces layout costs. The present invention has high practical and promotional value. 7 DRAWINGS Standby power supply Switching circuit Switching PC interface circuit Control center Sensor - - - - - - - - - - - - - - - - - - - cete Mobile L phone APP Electric device FIG. 1 Function realization Status display Software layer TinyOS TIA Portal WinCC Hardware Wireless data terminal layer Datareceivingmodule DTD434M of Siemens FIG. 2

Description

DRAWINGS
Standby power supply
Switching circuit
Switching PC interface circuit Control center Sensor --- --- - --- -- --- - --- cete Mobile L phone APP Electric device
FIG. 1
Status Function realization display
Software layer TinyOS TIA Portal WinCC
Hardware Wireless data terminal layer Datareceivingmodule DTD434M of Siemens
FIG. 2
TECHNICAL FIELD The present invention belongs to the technical field of power monitoring and control, and particularly relates to a wireless monitoring and control system applied in a factory. BACKGROUND According to the electricity consumption policy, China implements a two-staged electricity price for large industrial electricity consumption with a transformer capacity of 315 KVA or above. Its essence is to divide the electricity price into two parts: the basic electricity price and the watt-hour power price. The basic electricity price is calculated according to the transformer capacity or the maximum demand of industrial enterprises (i.e., the maximum average load every 15 min in a month), such that a power supply department signs a contract with an electricity consumption department to determine a quota, which is fixed on a monthly basis and does not depend on the actual amount of electricity consumed. The watt-hour power price is calculated according to the actual electricity consumption of an electricity consumption department. Every year when large industrial users sign power purchase contracts with a power grid company, a larger maximum demand means a more basic electricity price charged. The practical significance of the present invention is to add a standby power supply in a factory, reduce electricity consumption on the power grid side for large industrial users, ensure that the actual maximum demand on the power grid side does not exceed the value at the time of signing the contract (fines shall be paid if the demand exceeds the value), and calculate an optimal power purchase solution, thus reducing electricity expenses for the factory. A wireless sensor monitoring network is one of the important research contents of a smart factory environmental data monitoring system, and is a key technology to constitute a perception layer of the Internet of Things. The wireless sensor network brings a new information acquisition technology, analysis technology, processing technology and transmission mode. It is an important medium to connect a virtual network with the real world. The wireless sensor network extends from an information network to an object network to acquire and sense environmental data in real time instead of manual acquisition, and is considered as one of the ten key technologies to change the world in the 21st century. In recent years, the application of wireless sensor networks in factories, workshops, warehouses and buildings to complete environmental data monitoring and early warning based on the concept of the Internet of Things is gradually extended, expanding the penetration of application of the Internet of Things and promoting the rapid development of the Internet of Things. The wireless sensor used by the present invention is a wireless electricity consumption sensor. A PLC is a novel universal automatic control device, which integrates conventional relay control, a computer and a communication technology, and has the advantages of strong control functions, high reliability, flexibility and convenience in use, easiness of extension, etc. In the present invention, a communication module is installed on the PLC, so that a wireless control function can be realized. SUMMARY la
According to an aspect of the present invention, there is provided A wireless monitoring and control system applied in a factory, comprising a wireless electricity consumption sensor, a programmable logic controller (PLC) with a wireless communication module, a control center and a standby power supply, wherein the wireless electricity consumption sensor is installed on an electric device side; the wireless electricity consumption sensor is wirelessly connected to the control center; the control center is wirelessly connected to the PLC; the standby power supply is connected to a main power supply line of an electric device through a standby switching circuit; and the control center is configured with a maximum electricity consumption demand threshold and a comparison program; the wireless electricity consumption sensor senses the electricity consumption of the electric device; if the electricity consumption monitored by the wireless electricity consumption sensor is close to the maximum electricity consumption demand threshold, the PLC receives a command and controls switching of the standby power supply, and the standby power supply supplies power to the electric device. Also described herein is a monitoring and control system applied in a factory and based on a wireless electricity consumption sensor and a wireless control by a PLC via research on wireless sensors and PLCs. The system can sense the electricity consumption through the wireless electricity consumption sensor connected to an electric device, and through the analysis of data, the PLC controls the switching of a standby power supply, thus saving electricity expenditures for industrial users and establishing an Internet of Things in power systems (IOTIPS) based on a wireless electricity consumption sensor network. Also described herein is a wireless monitoring and control system applied in a factory, including a wireless electricity consumption sensor, a PLC with a wireless communication module, a control center and a standby power supply, where the wireless electricity consumption sensor is installed on an electric device side; the wireless electricity consumption sensor is wirelessly connected to the control center; the control center is wirelessly connected to the PLC; the standby power supply is connected to a main power supply line of an electric device through a standby switching circuit; and a maximum electricity consumption demand threshold and a comparison program are written in the control center. The wireless electricity consumption sensor monitors electrical parameters in real time and wirelessly sends the electrical parameters to the control center; the control center processes the parameters and sends a control command to the PLC; if the electricity consumption monitored by the wireless electricity consumption sensor is close to the maximum demand threshold, the PLC receives the command and controls the switching of the standby power supply, i.e., a power grid exits power supply and the standby power supply supplies power to the electric device. A PLC module uses a wireless PLC, which is optimized for remote measurement and control based on the features and performance of the conventional PLC. With regard to hardware, the PLC module further has a wireless communication function besides functions of input acquisition, relay control, timer and serial communication and the like of the conventional PLC. According to the present invention, the actual maximum demand on the power grid side does not exceed the value signed in the contract, thus reducing the electricity expense for the factory. Preferably, the standby power supply is a photovoltaic power generation system, which has obvious speed advantages. The system automatically switches to the photovoltaic power generation system, and then the system directly uses electric energy stored in a storage battery as power, which has a very short interval, thereby ensuring that the power supply in these occasions will not be interrupted. In addition, the photovoltaic power generation system as a new energy power supply tending to be mature can meet the current social demand for energy conservation. Preferably, the wireless electricity consumption sensor is composed of an electromagnetic isolation and acquisition unit, an electric energy conversion unit, an MCU, a wireless transmission unit, a configuration unit and a self-powered power supply conversion unit. The wireless electricity consumption sensor based on a ZigBee technology is a product of an electrical parameter acquisition module implemented by integrating an electromagnetic isolation principle, data acquisition, wireless communication and other technologies. The wireless electricity consumption sensor is mainly applicable to the fields of automatic control and remote control and implements real-time on-line data monitoring. Preferably, the control center is formed by a software layer and a hardware layer, the software layer includes a TinyOS system installed in an operating system of the control center, TIA Portal software and WinCC software, and the maximum electricity consumption demand threshold and the comparison program are stored in the TIA Portal software; the hardware layer includes a data receiving module and a wireless data terminal, the data receiving module receives data acquired by the wireless electricity consumption sensor, and sends the data to the TinyOS system for reading; after data processing by the TIA Portal software, the wireless data terminal sends a control instruction to the PLC, and finally a visual operation interface is designed by using the WinCC software. It is also possible to develop a mobile phone APP and visualize the interface on a mobile phone. Compared with the prior art, the present invention has the following beneficial effects: 1. The actual maximum demand on the power grid side does not exceed the value signed in the contract, thus reducing the electricity expense for the factory. 2. Components adopted by the present invention pertain to small compact wireless hardware, thereby achieving wireless information transmission in a factory and reducing layout costs. 3. A monitoring element of the present invention is the wireless electricity consumption sensor, and an IOTIPS can be established when the consumption reaches a certain scale. 4. The present invention uses the photovoltaic power generation system as a standby power supply module. The photovoltaic power generation system as a new mature energy power supply can save energy while achieving a power supply function. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic structural diagram of the present invention; and FIG. 2 is an enlarged view of a control center in FIG. 1. DETAILED DESCRIPTION The specific examples of the present invention are described in detail below with reference to the accompanying drawings. A wireless monitoring and control system applied in a factory includes a standby switching circuit, a wireless electricity consumption sensor, a PLC, a control center and a photovoltaic power generation system, where the photovoltaic power generation system is connected to a main power supply circuit of an electric device through the standby switching circuit. The PLC controls the on off of the standby switching circuit and a relay on a main switching circuit of a power grid. The specific installation of the system is shown in FIG. 1. The wireless electricity consumption sensor monitors electrical parameters in real time and wirelessly sends the electrical parameters to the control center; the control center processes the parameters and sends a control command to the PLC; and the PLC receives the command and controls the switching of the standby power supply. As shown in FIG. 2, the control center is formed by a software layer and a hardware layer. The software layer receives and processes data and visualizes an interface. The hardware layer includes a data receiving module and a wireless data terminal and implements wireless receiving of data and wireless transmission of a control command. The data receiving module connected to a PC through a serial port receives data acquired by the wireless electricity consumption sensor, and then sends the data to a TinyOS system for reading. After data processing by TIA Portal software, the wireless data terminal DTD434M sends a control instruction to the PLC (the programming of the PLC is performed through the TIA Portal software). Finally a visual operation interface is designed by using WinCC software. Real-time on-line data monitoring can be implemented by using the wireless electricity consumption sensor. Medium and short distance wireless control can be implemented by using the PLC equipped with a communication module. The photovoltaic power generation system, as a standby power supply and a new energy power supply tending to mature, can save energy while achieving a power supply function. Components used in the present invention pertain to small compact wireless hardware, thereby achieving wireless information transmission in a factory and reducing layout costs.
The above are merely specific examples of the present invention, but the present invention is not limited thereto. The wireless detection of an electricity quantity and the wireless control of switches can be implemented by any factory. The wireless monitoring and control system can also be used in similar places in other related fields for monitoring and control. Any simple change, equivalent replacement, modification, or the like made to solve basically the same technical problems or achieve basically the same technical effects based on the present invention falls within the protection scope of the present invention. Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavor to which this specification relates.

Claims (4)

  1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: 1. A wireless monitoring and control system applied in a factory, comprising a wireless electricity consumption sensor, a programmable logic controller (PLC) with a wireless communication module, a control center and a standby power supply, wherein the wireless electricity consumption sensor is installed on an electric device side; the wireless electricity consumption sensor is wirelessly connected to the control center; the control center is wirelessly connected to the PLC; the standby power supply is connected to a main power supply line of an electric device through a standby switching circuit; and the control center is configured with a maximum electricity consumption demand threshold and a comparison program; the wireless electricity consumption sensor senses the electricity consumption of the electric device; if the electricity consumption monitored by the wireless electricity consumption sensor is close to the maximum electricity consumption demand threshold, the PLC receives a command and controls switching of the standby power supply, and the standby power supply supplies power to the electric device.
  2. 2. The wireless monitoring and control system applied in a factory according to claim 1, wherein the standby power supply is a photovoltaic power generation system.
  3. 3. The wireless monitoring and control system applied in a factory according to claim 1 or 2, wherein the wireless electricity consumption sensor is composed of an electromagnetic isolation and acquisition unit, an electric energy conversion unit, a micro-controller unit, a wireless transmission unit, a configuration unit and a self-powered power supply conversion unit.
  4. 4. The wireless monitoring and control system applied in a factory according to claim 1 or 2, wherein the control center is formed by a software layer and a hardware layer, the software layer comprises a TinyOS system, Totally Integrate Automation Portal Software and SIMATIC WinCC installed in an operating system of the control center, wherein the maximum electricity consumption demand threshold and the comparison program are stored in the Totally Integrate Automation Portal Software; the hardware layer comprises a data receiving module and a wireless data terminal, the data receiving module receives data acquired by the wireless electricity consumption sensor, and then sends the data to the TinyOS system for reading; after data processing by the Totally Integrate Automation Portal Software, the wireless data terminal sends a control instruction to the PLC, and finally a visual operation interface is designed by using the SIMATIC WinCC.
AU2020204595A 2019-12-06 2020-07-09 Wireless monitoring and control system applied in factory Active AU2020204595B2 (en)

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Application Number Priority Date Filing Date Title
CN201911239500.XA CN110806720A (en) 2019-12-06 2019-12-06 Wireless monitoring control system of mill
CN201911239500.X 2019-12-06

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Citations (4)

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Publication number Priority date Publication date Assignee Title
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US20120319491A1 (en) * 2011-01-18 2012-12-20 Sears Brands, Llc Methods and systems for providing an appliance hybrid mode
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US20150372539A1 (en) * 2013-02-13 2015-12-24 Carbontrack Pty Ltd System and method for monitoring and control of appliances

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110051325A1 (en) * 2009-09-02 2011-03-03 Kawasaki Michikata Power supply system
US20120319491A1 (en) * 2011-01-18 2012-12-20 Sears Brands, Llc Methods and systems for providing an appliance hybrid mode
US20140088780A1 (en) * 2012-09-26 2014-03-27 Hongxia Chen Automatic local electric management system
US20150372539A1 (en) * 2013-02-13 2015-12-24 Carbontrack Pty Ltd System and method for monitoring and control of appliances

Non-Patent Citations (5)

* Cited by examiner, † Cited by third party
Title
ALULEMA, D. et al., ‘An IoT-Based Remote Monitoring System for Electrical Power Consumption via Web-Application’, 2018 International Conference on Info Systems and Computer Science, 13-15 November 2018, Quito, Ecuador, pages 193-197. *
KIRUBASHANKAR, R. et al., ‘Design and Implementation of Web Based Remote Supervisory Control and Information System’, International Journal of Soft Computing and Engineering (IJSCE); Vol. 1, Issue 4, September 2011, pages 43-51. *
LIU, W. et al., ‘An IoT-enabled Approach for Energy Monitoring and Analysis of Die Casting Machines’, 25th CIRP Life Cycle Engineering (LCE) Conference, 30 April – 2 May 2018, Copenhagen, Denmark, pages 656-661. *
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