CN112859779A - Data acquisition and early warning system of airflow cut-tobacco drier - Google Patents
Data acquisition and early warning system of airflow cut-tobacco drier Download PDFInfo
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- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- G—PHYSICS
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Abstract
The invention discloses a data acquisition and early warning system of an airflow cut-tobacco drier.A field PLC is arranged on the airflow cut-tobacco drier; the OPC server is connected with the field PLC through an Ethernet link; the message conversion pushing module is connected with the OPC server; the time sequence database is connected with the message conversion pushing module and is used for storing the equipment parameters, the process control parameters and the process technological parameters forwarded by the message conversion pushing module; the ETL module is connected with the time sequence database and is used for extracting, converting and cleaning data in the time sequence database; the ROMS module is connected with the ETL module, and the ETL module is also used for storing the cleaned data into the ROMS module so that an upper layer application can extract required data from the ROMS module; wherein, the ROMS module is a non-relational database. The invention can record the parameters of the airflow cut-tobacco drier equipment and the parameters of the control process in time.
Description
Technical Field
The invention relates to the technical field of cigarette production, in particular to a data acquisition and early warning system of an airflow cut tobacco dryer.
Background
With the acceleration of the steps of reducing tar and harm of cigarettes, the airflow drying cut tobacco drying equipment is widely applied to cigarette enterprises. In order to meet the technological requirements of the cut tobacco making and drying process, the airflow drying and cut tobacco drying equipment needs to control equipment parameters such as oxygen content, natural gas flow, hot air temperature, moisture, steam flow, pressure and the like, so that a good cut tobacco drying effect can be achieved. The publication of white paper in an industrial internet platform (2019) has profound influence on the field of control of the cigarette industry, and real-time data such as parameters of air-flow drying and tobacco shred drying equipment, process control parameters, process technological parameters and the like are acquired and observed, and early warning performance is intelligently generated. Has important significance for improving the product quality.
For cigarette enterprises, the product quality is heavier than that of Mount Taishan. At present, reading equipment parameters, process control parameters and process technological parameters of an airflow cut-tobacco drier mainly depends on manual operation, and a WinCC control panel is used for recording the current parameters of the equipment according to quantity.
The prior art has the following defects for the data acquisition of the airflow cut-tobacco drier:
(1) whether manual work is carried out on time and quantity on equipment parameters, process control parameters and process technological parameters of the airflow cut-tobacco drier becomes the most critical factor influencing the accuracy of data. Due to the subjectivity of the personnel, the process has a high probability of error. Manual statistics recording is inefficient, wasting a large amount of human resources at the same time.
(2) The air flow cut tobacco dryer has the advantages of various equipment parameters, process control parameters and process technological parameters, heavy recording work, management of statistical results such as addition, deletion, modification and checking of records is extremely inconvenient along with increasing of statistical times, historical records are difficult to effectively guide production, and data lose historical significance and value.
(3) The manual recorded data cannot intervene production in real time, cannot monitor and early warn production states in real time, and is slow in response when the product quality defect is found.
Disclosure of Invention
The invention aims to provide a data acquisition and early warning system of an airflow cut-tobacco drier, which can be used for solving the defects in the prior art and recording the equipment parameters and the control process parameters of the airflow cut-tobacco drier in time.
The invention provides a data acquisition and early warning system of an airflow cut-tobacco drier, which comprises,
the field PLC is arranged on the airflow cut-tobacco drier and is used for acquiring equipment parameters, process control parameters and process technological parameters of the airflow cut-tobacco drier;
the OPC server is connected with the field PLC through an Ethernet link and is used for acquiring equipment parameters, process control parameters and process technological parameters of the airflow cut-tobacco drier output by the field PLC;
the information conversion and pushing module is connected with the OPC server and is used for acquiring equipment parameters, process control parameters and process technological parameters from the OPC server and forwarding the equipment parameters, the process control parameters and the process technological parameters;
the time sequence database is connected with the message conversion pushing module and is used for storing the equipment parameters, the process control parameters and the process technological parameters forwarded by the message conversion pushing module;
the ETL module is connected with the time sequence database and is used for extracting, converting and cleaning data in the time sequence database; the ROMS module is connected with the ETL module, and the ETL module is also used for storing the cleaned data into the ROMS module so that an upper layer application can extract required data from the ROMS module; wherein, the ROMS module is a non-relational database.
The data acquisition and early warning system of the airflow cut-tobacco drier is characterized in that the field PLC is provided with a sensor for acquiring equipment parameters, process control parameters and process technological parameters;
and the field PLC is also used for packaging the equipment parameters, the process control parameters and the process technological parameters acquired by the sensors through an OPC protocol.
The data acquisition and early warning system for the airflow cut-tobacco drier comprises the following steps:
s11, sending an acquisition message;
s12, judging whether a PLC response message is received; if yes, go to step S13; if not, go to step S17;
s13, writing the data message into a cache;
s14, analyzing the message in the cache;
s15, changing the online state of the equipment for caching and summarizing;
s16, starting time delay;
and S17, changing the acquisition address in turns.
The data acquisition and early warning system for the airflow cut-tobacco drier comprises, optionally, the working process of the message conversion pushing module comprises the following steps:
after system configuration and initialization are completed, a plurality of running threads are created;
wherein at least one of the running threads performs the steps of:
s21, accessing OPC data acquisition service;
s22, judging whether there is data, if yes, executing step S23; if not, go to step S21;
s23, analyzing the data;
s24, writing into a queue;
among the plurality of running threads, at least one running thread performs the following steps:
s31, judging whether the queue has data, if yes, executing step S32, if no, executing step S31;
s32, the data is passed into a downstream service.
The data acquisition and early warning system for the airflow cut-tobacco drier comprises an ETL module, a gas-liquid separator and a gas-liquid separator:
s41, receiving message conversion push service data;
s42, judging whether the dead pixel is present by using the box chart; if not, go to step S43; if yes, go to step S45;
s43, carrying out 3 sigma dead pixel judgment; if not, go to step S44; if the pixel is a dead pixel, go to step S45;
s44, calling data storage service, and executing step S41 after completion;
s45, removing dead pixels;
s46, interpolation and filling; and performs step S44 after completion;
the data acquisition and early warning system for the airflow cut-tobacco drier is optionally further used for realizing the following early warning steps:
s51, accessing message conversion push service;
s52, judging whether there is data, if yes, executing step S53, if not, executing step S51;
s53, judging whether the current collection value is abnormal; if yes, early warning is carried out; if not, step S51 is performed.
The data acquisition and early warning system for the airflow cut-tobacco drier is characterized in that the field PLC is optionally connected with the OPC server through an ethernet switch.
Compared with the prior art, the invention has at least the following beneficial effects:
the parameters of the pneumatic drying and cut-tobacco drying equipment, the process control parameters, the process technological parameters and the like are collected and observed in real time, and early warning behaviors are intelligently generated. Has important significance for improving the product quality.
The production process of the air flow cut-tobacco drier is monitored in real time, and when the parameters are abnormal, an early warning signal is sent to the on-duty process personnel and the management personnel.
And after the system is on line, a one-month time interval is randomly extracted for testing, and the data dead pixel rejection rate reaches 100%. And no packet loss phenomenon occurs in data storage. The parameter early warning service has 100% of early warning accuracy for equipment parameters, process control parameters and process technological parameter abnormity.
The number of the data acquisition points is within the range of 0-5000, the data acquisition frequency is 250 ms/time-1000 ms/time, the increase of the number of the data acquisition points does not influence the communication quality, and the data acquisition performance requirements are completely met; 2. when the number of the sampling points is increased, the response time of the message conversion push service is increased, but when the maximum number of the sampling points is 5000, the response time is 123ms, and the industrial production requirement is completely met.
Drawings
FIG. 1 is a block diagram of a data acquisition and early warning system of an airflow cut-tobacco drier according to the present invention;
FIG. 2 is a flow chart of the steps of the data acquisition process proposed by the present invention;
FIG. 3 is a flow chart of steps in which the message conversion push module operates;
FIG. 4 is a flow chart of the steps of a data cleansing process;
fig. 5 is a flow chart of the early warning step.
Detailed Description
The embodiments described below with reference to the drawings are illustrative only and should not be construed as limiting the invention.
The embodiment of the invention comprises the following steps: referring to fig. 1 to 5, the present invention provides a data acquisition and early warning system for an airflow cut-tobacco drier, which comprises,
the field PLC is arranged on the airflow cut-tobacco drier and is used for acquiring equipment parameters, process control parameters and process technological parameters of the airflow cut-tobacco drier;
the OPC server is connected with the field PLC through an Ethernet link and is used for acquiring equipment parameters, process control parameters and process technological parameters of the airflow cut-tobacco drier output by the field PLC;
the information conversion and pushing module is connected with the OPC server and is used for acquiring equipment parameters, process control parameters and process technological parameters from the OPC server and forwarding the equipment parameters, the process control parameters and the process technological parameters;
the time sequence database is connected with the message conversion pushing module and is used for storing the equipment parameters, the process control parameters and the process technological parameters forwarded by the message conversion pushing module;
the ETL module is connected with the time sequence database and is used for extracting, converting and cleaning data in the time sequence database; the ROMS module is connected with the ETL module, and the ETL module is also used for storing the cleaned data into the ROMS module so that an upper layer application can extract required data from the ROMS module; wherein, the ROMS module is a non-relational database.
The field PLC (including the PLC substation) is connected with the OPC server through an Ethernet link, and the OPC server is connected with the message conversion push server through the Ethernet link. After receiving the data, the message conversion server forwards the message to a time sequence database for storage. And the ETL extracts, converts and cleans the data in the time sequence database, and accesses the data into the non-relational database, and all upper-layer applications can extract the required data from the non-relational database.
Therefore, the method can record the equipment parameters, the process control parameters and the process technological parameters of the airflow cut-tobacco drier at equal time intervals (for example, once every 2 s). Influenced by factors such as a sensor, a communication channel, noise and the like, a noise signal is generated in the data acquisition process, and the noise signal is judged and eliminated. The collected data is stored in a structured mode, and the maintenance and the availability of the collected data are improved.
The air flow cut-tobacco drier has various cut-tobacco drier sensors and complicated communication channels. Therefore, different sensors at the bottom layer need to be packaged through an OPC protocol, and a configurable interface for data acquisition and access is established. Meanwhile, in order to meet the requirement of data acquisition frequency, a data acquisition frequency control interface is developed. Specifically, sensors for acquiring equipment parameters, process control parameters and process technological parameters are arranged on the field PLC; and the field PLC is also used for packaging the equipment parameters, the process control parameters and the process technological parameters acquired by the sensors through an OPC protocol.
Referring to fig. 2, the data acquisition process of the sensor includes the following steps:
s11, sending an acquisition message;
s12, judging whether a PLC response message is received; if yes, go to step S13; if not, go to step S17;
s13, writing the data message into a cache;
s14, analyzing the message in the cache;
s15, changing the online state of the equipment for caching and summarizing;
s16, starting time delay;
and S17, changing the acquisition address in turns.
In particular, message conversion and pushing needs to have high throughput, persistent data storage, easy expansion, easy maintenance and other production performances. The invention uses multithreading to push the data collected by the data collection service, provides real-time data for downstream service and develops a real-time data push interface. The working process of the message conversion pushing module comprises the following steps:
referring to fig. 3, after system configuration and initialization are completed, a plurality of running threads are created;
wherein at least one of the running threads performs the steps of:
s21, accessing OPC data acquisition service;
s22, judging whether there is data, if yes, executing step S23; if not, go to step S21;
s23, analyzing the data;
s24, writing into a queue;
among the plurality of running threads, at least one running thread performs the following steps:
s31, judging whether the queue has data, if yes, executing step S32, if no, executing step S31;
s32, the data is passed into a downstream service.
Because the air flow cut tobacco dryer cut tobacco drying equipment is not used for 24-hour full-time production, the accumulated amount of supplied materials has obvious stub bar stage, stable stage and tail stage in the production process, and the production has the condition of material breakage due to the influence of the supplied materials in the production and the like. Non-production data needs to be eliminated, and marking processing is carried out on the data of a material head, a material tail, a material middle and a material breakage. Meanwhile, under the influence of various factors such as a network and a sensor, dead spots and outliers are generated, and the dead spots and the outliers need to be identified and removed. Therefore, the data management interface is developed to accurately manage the data and provide effective data for subsequent modules of the system. The cleaning process of the ETL module for the equipment parameters, the process control parameters, and the process parameters includes the following steps, referring to fig. 4,
s41, receiving message conversion push service data;
s42, judging whether the dead pixel is present by using the box chart; if not, go to step S43; if yes, go to step S45;
s43, carrying out 3 sigma dead pixel judgment; if not, go to step S44; if the pixel is a dead pixel, go to step S45;
s44, calling data storage service, and executing step S41 after completion;
s45, removing dead pixels;
s46, interpolation and filling; and performs step S44 after completion;
in order to meet the requirement of horizontal expansion (increase, deletion and modification of collection points, collection points and collection frequency) of the data collection service during specific implementation, a non-relational database MongoDB is used as storage, and a data access interface is developed.
In order to realize the parameter early warning function, according to the process parameters, when the equipment parameters of the airflow cut-tobacco drier, the process control parameters and the process parameters are abnormal, the on-duty personnel are early warned, and therefore, an early warning interface module is developed. Referring to fig. 5, the method specifically includes the following steps:
s51, accessing message conversion push service;
s52, judging whether there is data, if yes, executing step S53, if not, executing step S51;
s53, judging whether the current collection value is abnormal; if yes, early warning is carried out; if not, step S51 is performed.
When the method is implemented, the upper computer program can be developed by adopting a C/S framework.
Further, the field PLC is connected with the OPC server through an Ethernet switch in a network mode. In order to make the aforementioned objects, features and advantages of the present invention comprehensible, a site deployment and a use of the system will be described in detail.
The field devices are as follows, PLC: siemens 300, ethernet switch: siemens X206-1, an upper computer, an operating system: windows7 professional edition, ethernet card: intel (R) Ethernet Connection I217-LM, communication protocol: TCP/IP.
In order to test the practical effect of the invention, practical tests are carried out in three aspects of acquisition point location quantity, frequency pressure test, message conversion push pressure test, data management service, data storage service and parameter early warning service test.
(1) The test is used for testing the OPC data acquisition communication quality under different data acquisition point position quantity and frequency, the quality description index adopts the numerical value description in the OPC DA standard specification, the value range is 0-192, the signal quality is the worst when the numerical value is 0, the signal quality is the best when the numerical value is 192, and the average value of the communication quality of all the acquisition points is used as an evaluation result.
(2) The test performs pressure test on the message conversion push service under different data acquisition point location numbers and frequencies, and the index of the pressure test evaluation is the response time of the service at different point location numbers and frequencies.
Wherein the test results of (1) and (2) are shown in the following table:
from the above table, it can be seen that: 1. the number of the data acquisition points is within the range of 0-5000, the data acquisition frequency is 250 ms/time-1000 ms/time, the increase of the number of the data acquisition points does not influence the communication quality, and the data acquisition performance requirements are completely met; 2. when the number of the sampling points is increased, the response time of the message conversion push service is increased, but when the maximum number of the sampling points is 5000, the response time is 123ms, and the industrial production requirement is completely met.
(3) Data administration service, data storage service, parameter early warning service
After the system is on line, the inventor randomly extracts a one-month time interval for testing, and finds that the defective pixel rejection rate of the data reaches 100%. And no packet loss phenomenon occurs in data storage. The parameter early warning service has 100% of early warning accuracy for equipment parameters, process control parameters and process technological parameter abnormity.
The invention has at least the following beneficial effects:
(1) and recording the equipment parameters, the process control parameters and the process technological parameters of the airflow cut-tobacco drier at equal time intervals (for example, once every 2 s).
(2) Influenced by factors such as a sensor, a communication channel, noise and the like, a noise signal is generated in the data acquisition process, and the noise signal is judged and eliminated.
(3) The collected data is stored in a structured mode, and the maintenance and the availability of the collected data are improved.
(4) And (4) early warning in real time of the production state, if the equipment parameters and the process control parameters in the monitoring period and the process technological parameters are in an abnormal value range, pushing early warning information to related workers.
The construction, features and functions of the present invention are described in detail in the embodiments illustrated in the drawings, which are only preferred embodiments of the present invention, but the present invention is not limited by the drawings, and all equivalent embodiments modified or changed according to the idea of the present invention should fall within the protection scope of the present invention without departing from the spirit of the present invention covered by the description and the drawings.
Claims (7)
1. The utility model provides an air current cut-tobacco drier data acquisition and early warning system which characterized in that: comprises the steps of (a) preparing a mixture of a plurality of raw materials,
the field PLC is arranged on the airflow cut-tobacco drier and is used for acquiring equipment parameters, process control parameters and process technological parameters of the airflow cut-tobacco drier;
the OPC server is connected with the field PLC through an Ethernet link and is used for acquiring equipment parameters, process control parameters and process technological parameters of the airflow cut-tobacco drier output by the field PLC;
the information conversion and pushing module is connected with the OPC server and is used for acquiring equipment parameters, process control parameters and process technological parameters from the OPC server and forwarding the equipment parameters, the process control parameters and the process technological parameters;
the time sequence database is connected with the message conversion pushing module and is used for storing the equipment parameters, the process control parameters and the process technological parameters forwarded by the message conversion pushing module;
the ETL module is connected with the time sequence database and is used for extracting, converting and cleaning data in the time sequence database; the ROMS module is connected with the ETL module, and the ETL module is also used for storing the cleaned data into the ROMS module so that an upper layer application can extract required data from the ROMS module; wherein, the ROMS module is a non-relational database.
2. The airflow cut-tobacco drier data acquisition and early warning system of claim 1, wherein: the field PLC is provided with a sensor for acquiring equipment parameters, process control parameters and process technological parameters;
and the field PLC is also used for packaging the equipment parameters, the process control parameters and the process technological parameters acquired by the sensors through an OPC protocol.
3. The airflow cut-tobacco drier data acquisition and early warning system of claim 2, wherein: the data acquisition process of the sensor comprises the following steps:
s11, sending an acquisition message;
s12, judging whether a PLC response message is received; if yes, go to step S13; if not, go to step S17;
s13, writing the data message into a cache;
s14, analyzing the message in the cache;
s15, changing the online state of the equipment for caching and summarizing;
s16, starting time delay;
and S17, changing the acquisition address in turns.
4. The airflow cut-tobacco drier data acquisition and early warning system of claim 1, wherein: the working process of the message conversion pushing module comprises the following steps:
after system configuration and initialization are completed, a plurality of running threads are created;
wherein at least one of the running threads performs the steps of:
s21, accessing OPC data acquisition service;
s22, judging whether there is data, if yes, executing step S23; if not, go to step S21;
s23, analyzing the data;
s24, writing into a queue;
among the plurality of running threads, at least one running thread performs the following steps:
s31, judging whether the queue has data, if yes, executing step S32, if no, executing step S31;
s32, the data is passed into a downstream service.
5. The airflow cut-tobacco drier data acquisition and early warning system of claim 1, wherein: the cleaning process of the ETL module for the equipment parameters, the process control parameters and the process technological parameters comprises the following steps:
s41, receiving message conversion push service data;
s42, judging whether the dead pixel is present by using the box chart; if not, go to step S43; if yes, go to step S45;
s43, carrying out 3 sigma dead pixel judgment; if not, go to step S44; if the pixel is a dead pixel, go to step S45;
s44, calling data storage service, and executing step S41 after completion;
s45, removing dead pixels;
s46, interpolation and filling; and performs step S44 after completion.
6. The airflow cut-tobacco drier data acquisition and early warning system of claim 5, wherein: the method is also used for realizing the following early warning steps:
s51, accessing message conversion push service;
s52, judging whether there is data, if yes, executing step S53, if not, executing step S51;
s53, judging whether the current collection value is abnormal; if yes, early warning is carried out; if not, step S51 is performed.
7. The airflow cut-tobacco drier data acquisition and early warning system of claim 1, wherein: and the field PLC is connected with the OPC server through an Ethernet switch.
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Application publication date: 20210528 |