CN211403226U - Intelligent powder spraying line based on big data monitoring - Google Patents
Intelligent powder spraying line based on big data monitoring Download PDFInfo
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- CN211403226U CN211403226U CN202020537311.2U CN202020537311U CN211403226U CN 211403226 U CN211403226 U CN 211403226U CN 202020537311 U CN202020537311 U CN 202020537311U CN 211403226 U CN211403226 U CN 211403226U
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Abstract
The utility model discloses an intelligence line of dusting based on big data monitoring, including production line PLC on the line of dusting, and be used for the overhead conveyer of last work piece and lower work piece of being connected with production line PLC respectively, the water tank in hot water warehouse wash and the water warehouse wash, water tank and water purification machine in the pure water warehouse wash, the storehouse of degreasing in advance, water tank and medicament jar in degreasing storehouse and silane spray storehouse, oven in the stoving storehouse and in the solidification storehouse, spray reciprocating engine in the dusting room, still include the main control system, and the collection system who is connected with the main control system respectively, the accumulator, the display, the alarm, high in the clouds software, production line PLC is connected with the main control system. Safety index data, quality index data, energy data and consumptive material data in the technological process are collected through the collection system, are analyzed and processed through the monitoring host computer, and are transmitted to the storage device, the display, the alarm and the cloud software, so that unmanned management of the powder spraying line can be realized, and industrial transformation and intelligent upgrading are effectively promoted.
Description
Technical Field
The utility model relates to a control management field of application trade, concretely relates to intelligence line of dusting based on big data monitoring.
Background
The coating process and equipment in China are developed quickly. Has great gap in the aspects of environmental protection, energy conservation, emission reduction and resource utilization rate. VOC discharge of a plurality of coating lines does not reach the standard, energy consumption, water consumption and coating material consumption of unit coating area are high, and enterprise cost is increased because a factory does not have corresponding supervision measures. Meanwhile, the electrostatic value in the production line, the concentration in the spraying chamber and the waste gas in the oven are also important links influencing the safe production of the workshop.
The metal plate metal part relates to a complex process and a working environment with strong acidity and alkalinity before coating, the acid value, the alkalinity value, the temperature value, the energy loss (medicament, electricity and fuel gas) and the electrostatic value, the concentration of a powder spraying chamber, the combustible point value and the dust concentration of hot circulating air in an oven in the environment have very important links for the whole factory, and the waste water of the factory waste water is discharged to a sewage station in an overproof manner and simultaneously causes medicament waste, so that the related numerical value, automatic supply, safety warning and production halt are required to be monitored in real time when necessary.
In chinese utility model patent CN201821877571.3, "an intelligent coating line based on unmanned management" mention and utilize sensor to gather safety index data, quality index data, energy data and consumptive material data in the coating technology process, and then realize coating line's unmanned management to effectively promote industry transformation and intelligent upgrading. However, the safety monitoring is not in place, and the personnel entering the site are not monitored, which can cause the unqualified personnel to enter the adverse effects on the quality and efficiency of the powder spraying line and the harm to the personnel entering the site caused by the environment of the powder spraying line; flame detection is not carried out in the spraying chamber, so that detonation accidents caused by ignition sources generated by static electricity or other reasons cannot be prevented.
SUMMERY OF THE UTILITY MODEL
The utility model provides an intelligence line of dusting based on big data monitoring can carry out real-time supervision and warning to various indexes on the line of dusting based on big data monitoring to the security and the production quality of effective guarantee line of dusting.
In order to achieve the above object, the utility model adopts the following technical scheme:
an intelligent powder spraying line based on big data monitoring comprises a hanging conveyor for an upper workpiece and a lower workpiece, water tanks in a hot water washing bin and a water washing bin, a water tank and a water purifier in a pure water washing bin, water tanks and medicament tanks in a pre-degreasing bin, a degreasing bin and a silane spraying bin, ovens in a drying bin and a curing bin, a spraying reciprocating machine and a humidifier in a powder spraying chamber, a production line PLC, an acquisition device, a monitoring host, a storage, a display, an alarm and cloud software;
the collecting device comprises a free alkalinity sensor, a pH sensor, a pressure sensor, a conductivity sensor, a temperature sensor, a humidity sensor, a dust concentration sensor, a combustible gas concentration sensor, a high-temperature dust sensor, a waste gas concentration sensor, an electrostatic sensor, an infrared flame detector, a grounding resistance sensor, a human face recognition sensor, a medicament quantity sensor, a powder flow sensor, an electric energy consumption sensor, a water flow sensor, a gas flow sensor, an atomization gas pressure detector, a compressed air quantity sensor and a camera; the camera, the sensors, the detectors, the storage, the display, the alarm and the cloud software are respectively connected with the monitoring host;
the monitoring host comprises a shell, and an acquisition module, a central processing module, a wireless communication module, a wired communication module and a display module which are arranged in the shell;
the wired communication module is electrically connected with a communication interface;
the wireless communication module comprises one or more of a Bluetooth module, a WiFi module, a GSM module, a GPRS module, a CDMA2000 module, a WCDMA module, a TD-SCDMA module, a Zigbee module and a LoRa module;
the acquisition module is connected with the wired communication module, is connected with the acquisition device through a communication interface and is used for realizing the real-time acquisition of each monitoring index on the powder spraying line;
the central processing module is respectively connected with the acquisition module, the wireless communication module, the wired communication module and the display module and is used for processing, summarizing, counting, analyzing and transmitting data;
the display module comprises a display circuit and a display screen, and the display screen is arranged on the shell and used for displaying monitoring data in real time.
Preferably, the communication interface includes an RS485 interface and an ethernet interface.
Preferably, a temperature sensor is arranged in a water tank of the hot water washing bin, and a pressure sensor is arranged on the spraying pipeline;
temperature sensors, free alkalinity sensors and medicament quantity sensors are arranged in the water tanks of the pre-degreasing bin and the degreasing bin, and pressure sensors are arranged on the spraying pipelines;
pH sensors are arranged in water tanks of the pure water washing bin and each level of water washing bin, and pressure sensors are arranged on spraying pipelines;
a conductivity sensor is also arranged in the water tank of the pure water washing bin;
a pH sensor, a temperature sensor, a conductivity sensor and a medicament quantity sensor are arranged in a water tank of the silane spraying bin, and a pressure sensor is arranged on a spraying pipeline;
the temperature sensor, the combustible gas concentration sensor, the waste gas concentration sensor and the high-temperature dust sensor are arranged in the oven of the drying bin and the curing bin, and a gas quantity sensor is arranged on a gas pipeline of the oven;
a face recognition sensor and a camera are arranged at the inlet of the powder spraying chamber, an electrostatic value sensor, a grounding resistance sensor, a humidity sensor, a temperature sensor, a dust concentration sensor and an infrared flame detector are arranged in the powder spraying chamber, a powder flow sensor and a compressed air quantity sensor are arranged on a powder gun of the spraying reciprocating machine, and an atomization pressure detector is arranged on an atomization pipeline of the spraying reciprocating machine;
each sensor, each detector and camera are connected with the monitoring host through RS485 interfaces, and the monitoring host is connected with the storage, the display, the alarm and the cloud software through the wireless communication module.
Preferably, the production line PLC is respectively connected with the suspension conveyor, a water pump in the medicament tank, a water purifier, a burner and a fan of an oven, a spraying reciprocating machine and a humidifier, medicament pipeline electromagnetic valves are arranged on pipelines between the medicament tank and the water tank, a plurality of groups of the medicament pipeline electromagnetic valves are respectively connected with the production line PLC, and the production line PLC is connected with the monitoring host through an Ethernet interface.
Due to the structure, the beneficial effects of the utility model reside in that:
1. the utility model provides an intelligence line of dusting, through adopting multiple different sensor, the detector gathers the safety index data in the technological process of dusting, quality index data, energy data and consumptive material data, and through analysis and processing of monitoring host computer to the data, construct real-time data curve or data report form and show and save, not only be convenient for carry out intelligent control in real time to the technological process, the storage and the inquiry efficiency to data in the past have more been improved, through comparing real-time data with preset reference index data, can in time send automatic supply signal in time alarm signal when some index surpass reference index data, realize the unmanned intelligent management of line of dusting, thereby effectively promote industry transformation and intelligent upgrading.
2. According to the intelligent powder spraying line, through the arrangement of the camera and the face recognition sensor, identity recognition is carried out on personnel entering a powder spraying chamber, and whether a hat, glasses, a mask and clothes worn by the personnel enter the powder spraying chamber are monitored to meet related regulations or not, so that production safety and personnel safety are guaranteed;
3. according to the intelligent powder spraying wire, the illumination intensity of flame combustion and the flicker frequency of flame in the powder spraying chamber are detected through the arrangement of the infrared flame detector, and then corresponding measures are taken according to the detection condition, so that deflagration accidents caused by ignition sources generated due to static electricity or other reasons are effectively prevented, and casualties or property loss is reduced;
4. the intelligent powder spraying line can be connected with a user terminal through the setting of cloud software, and can also provide functions such as access management, data persistence and service logic processing through a software system.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly described below.
Fig. 1 is a schematic diagram of the system structure of the present invention.
Detailed Description
The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings of the present invention. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative efforts belong to the protection scope of the present invention.
As shown in fig. 1, this embodiment provides an intelligence line of dusting based on big data monitoring, including the overhead conveyer who is used for last work piece and lower work piece on the line of dusting, the water tank in hot water washing storehouse and the washing storehouse, water tank and the water purification machine in the pure water washing storehouse, water tank and the medicament jar in pre-degreasing storehouse, degreasing storehouse and the silane spraying storehouse, the oven in the stoving storehouse and in the solidification storehouse, spray coating reciprocating engine and humidifier in the room of dusting, and production line PLC.
The powder spraying line is also provided with a collecting device, a monitoring host, a storage, a display, an alarm and cloud software, and is used for realizing intellectualization of the powder spraying line based on big data monitoring;
the collecting device comprises a free alkalinity sensor (DR-YLJD01), a pH sensor (DR-H11S/H-760S), a pressure sensor (DR-PXGRT3), a conductivity sensor (DR-C11S/H-900S), a temperature sensor (DR-PXGRT), a humidity sensor (NS-WDM27) and an atomization air pressure detector (MIK-P300) which are used as quality monitoring plates;
a dust concentration sensor (GGG-1000), a combustible gas concentration sensor (6310CO), a high-temperature dust sensor (GP2Y1014AU), an exhaust gas concentration sensor (PID-A1), an electrostatic sensor (SL-038A), an infrared flame detector (JTGB-UF-C35 Ex), a grounding resistance sensor (ZC29B-2), a face recognition sensor (B5T-007001) and a camera (IMX220) as a safety monitoring panel;
a drug quantity sensor (DRSWD-LG) and a powder flow sensor (CT-08-07) which are used as consumable monitoring plates;
an electric energy consumption sensor (DTS1053), a water flow sensor (DN50-10), a gas flow sensor (MQ-5) and a compressed air flow sensor (MF40034008) are used as energy monitoring plates.
The camera, the sensors, the detectors, the storage (CY7C4205-10AC), the display (SAMSUNG-S24D360HL), the alarm (MTC-600) and the cloud software are respectively connected with the monitoring host.
The monitoring host can adopt a model I7-7700, and comprises a shell, and an acquisition module, a central processing module, a wireless communication module, a wired communication module and a display module which are arranged in the shell;
the wired communication module is electrically connected with a communication interface, and in this embodiment, the communication interface includes an RS485 interface and an ethernet interface;
the acquisition module is connected with the wired communication module, is connected with the acquisition device through a communication interface and is used for realizing the real-time acquisition of each monitoring index on the powder spraying line;
the central processing module is respectively connected with the acquisition module, the wireless communication module, the wired communication module and the display module and is used for processing, summarizing, counting, analyzing and transmitting data;
the wireless communication module comprises any one or more of a Bluetooth module, a WiFi module, a GSM module, a GPRS module, a CDMA2000 module, a WCDMA module, a TD-SCDMA module, a Zigbee module and a LoRa module;
the display module comprises a display circuit and a display screen, and the display screen is arranged on the shell and used for displaying monitoring data in real time.
Wherein a temperature sensor is arranged in a water tank of the hot water washing bin, and a pressure sensor is arranged on the spraying pipeline;
temperature sensors, free alkalinity sensors and medicament quantity sensors are arranged in the water tanks of the pre-degreasing bin and the degreasing bin, and pressure sensors are arranged on the spraying pipelines;
pH sensors are arranged in water tanks of the pure water washing bin and each level of water washing bin, and pressure sensors are arranged on spraying pipelines;
a conductivity sensor is also arranged in the water tank of the pure water washing bin;
a pH sensor, a temperature sensor, a conductivity sensor and a medicament quantity sensor are arranged in a water tank of the silane spraying bin, and a pressure sensor is arranged on a spraying pipeline;
the temperature sensor, the combustible gas concentration sensor, the waste gas concentration sensor and the high-temperature dust sensor are arranged in the oven of the drying bin and the curing bin, and a gas quantity sensor is arranged on a gas pipeline of the oven;
a face recognition sensor and a camera are arranged at the inlet of the powder spraying chamber, an electrostatic value sensor, a grounding resistance sensor, a humidity sensor, a temperature sensor, a dust concentration sensor and an infrared flame detector are arranged in the powder spraying chamber, a powder flow sensor and a compressed air quantity sensor are arranged on a powder gun of the spraying reciprocating machine, and an atomization pressure detector is arranged on an atomization pipeline of the spraying reciprocating machine;
each sensor, each detector and camera are connected with the monitoring host through RS485 interfaces, and the monitoring host is connected with the storage, the display, the alarm and the cloud software through the wireless communication module.
In this embodiment, the production line PLC (6ES7-214-1AG40-0XB0) is connected to the suspension conveyor, the water pump in the chemical tank, the water purifier, the burner and fan of the oven, the spraying reciprocating machine, and the humidifier, the pipeline between the chemical tank and the water tank is provided with chemical pipeline electromagnetic valves, a plurality of sets of the chemical pipeline electromagnetic valves are connected to the production line PLC, and the production line PLC is connected to the monitoring host computer through an ethernet interface. The medicament tank is a container which is connected with the water tanks of the pre-degreasing bin, the degreasing bin and the silane spraying bin and is used for containing medicaments, and the medicaments in the medicament tank are injected into the water tanks through the water pumps.
The process steps of the powder spraying line, monitoring points involved in the process and data acquisition and analysis are briefly described by adopting a table.
The electrostatic value, the ground resistance value, the dust concentration value of a powder spraying room, the dust concentration of an oven and the concentration value of combustible waste gas (C0, CH4), and the flame detection value of the powder spraying room are important safety indexes in the powder spraying process, the powder spraying room is monitored, the potential safety hazard of a production line is helped to be mastered in real time, when relevant parameters exceed preset safety values, red mark display is carried out on a display screen of a monitoring host, data are transmitted to a display and an alarm, synchronous real-time display in a generation area and an office is carried out through the display screen and the display, acousto-optic alarm prompt is carried out through the alarm, and the production safety can be effectively guaranteed.
The camera, the face identification sensor that powder room entry set up carry out identification to the personnel that get into the powder room to and monitor cap, glasses, gauze mask, the clothes that get into personnel and dress, whether accord with relevant regulation, powder room entry still is provided with automatic door closing system (automatic door closing system adopts prior art) in this embodiment, further assurance production safety and personnel's safety.
The temperature value, the humidity value, the pH value, the free base number value, the conductivity value, the pressure value and the humidity value are directly reflected by the quality in the powder spraying process, the parameters are monitored in real time, the quality condition of the production process can be mastered in real time, the condition of mass deviation can be displayed on a display screen in time, and the warning is given out through sound and light.
The energy monitoring plate and the consumable monitoring plate are mainly used for monitoring the energy consumption conditions of related energy sources in the powder spraying process, and when the monitoring host judges that external supply is needed according to the parameters monitored by the corresponding medicament quantity sensors, the monitoring host sends a supply instruction to the production line PLC through the Ethernet, the electromagnetic valves of corresponding pipelines and the water pumps in the medicament tanks are opened, and medicament supply is carried out from the medicament tanks to the corresponding water tanks.
Meanwhile, the monitoring host can control the devices such as a suspension conveying mechanism, a spraying reciprocating machine and a burner, a fan and a humidifier of an oven of the production line through the PLC of the production line so as to realize synchronous control of all the devices on the production line.
The monitoring host can also be connected with a user terminal through a cloud software interface and can also provide access management, data persistence and service logic processing through a software system, and the monitoring host mainly comprises five functional modules:
basic platform and access management: establishing a gateway interface of a hardware acquisition and cloud platform, receiving the structured data from the intelligent equipment layer, storing and backing up the data in a centralized manner, and providing the data to other application systems for use according to the appointed authority; carrying out relevant protocol conversion, equipment authentication and equipment management; and distributing the service and accessing the gateway.
And (3) alarm management: setting an alarm threshold value; judging and reporting an alarm; notification of an alarm; and querying alarm history records.
Automatic management: setting automatic addition of the medicament; and setting abnormal production line stop.
User and rights management: the authority of the user can be edited and set, and the access control of the platform is strictly carried out according to the difference of the roles and the authority; and tracking the use condition of the user, such as login records, operation logs and the like.
Information management: managing metadata of the equipment, wherein all metering points managed and installed acquire the number of various sensors in real time; and (4) information state management, namely displaying the access condition of the enterprise to various information in real time.
Report display and external interface: providing historical report query; and (4) external interface of data.
The utility model provides an intelligence line of dusting, through adopting the safe index data of multiple different sensor collection in the technological process of dusting, the quality index data, energy data and consumptive material data, and through analysis and processing of monitoring host computer to the data, construct real-time data curve or data report form and show and save, not only be convenient for carry out real-time intelligent control to the technological process, the storage and the inquiry efficiency to data in the past have more improved, through comparing real-time data with preset reference index data, can in time send automatic supply signal in time alarm signal when some index surpass reference index data, realize that the unmanned of line of dusting can only manage, thereby effectively promote industry transformation and intelligent upgrading.
The above is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and various modifications and changes will occur to those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (4)
1. The utility model provides an intelligence line of dusting based on big data monitoring, including the conveyer that hangs that is used for last work piece and lower work piece on the line of dusting, the water tank in hot water washing storehouse and the washing storehouse, water tank and water purification machine in the pure water washing storehouse, in advance degrease storehouse, degrease storehouse and silane spray water tank and medicament jar in the storehouse, oven in the stoving storehouse and in the solidification storehouse, indoor spraying reciprocating engine and humidifier of dusting to and production line PLC, its characterized in that: the system also comprises a collecting device, a monitoring host, a storage, a display, an alarm and cloud software;
the collecting device comprises a free alkalinity sensor, a pH sensor, a pressure sensor, a conductivity sensor, a temperature sensor, a humidity sensor, a dust concentration sensor, a combustible gas concentration sensor, a high-temperature dust sensor, a waste gas concentration sensor, an electrostatic sensor, an infrared flame detector, a grounding resistance sensor, a human face recognition sensor, a medicament quantity sensor, a powder flow sensor, an electric energy consumption sensor, a water flow sensor, a gas flow sensor, an atomization gas pressure detector, a compressed air quantity sensor and a camera;
the camera, the sensors, the detectors, the storage, the display, the alarm and the cloud software are respectively connected with the monitoring host;
the monitoring host comprises a shell, and an acquisition module, a central processing module, a wireless communication module, a wired communication module and a display module which are arranged in the shell;
the wired communication module is electrically connected with a communication interface;
the wireless communication module comprises one or more of a Bluetooth module, a WiFi module, a GSM module, a GPRS module, a CDMA2000 module, a WCDMA module, a TD-SCDMA module, a Zigbee module and a LoRa module;
the acquisition module is connected with the wired communication module, is connected with the acquisition device through a communication interface and is used for realizing the real-time acquisition of each monitoring index on the powder spraying line;
the central processing module is respectively connected with the acquisition module, the wireless communication module, the wired communication module and the display module and is used for processing, summarizing, counting, analyzing and transmitting data;
the display module comprises a display circuit and a display screen, and the display screen is arranged on the shell and used for displaying monitoring data in real time.
2. An intelligent powder spray line according to claim 1, wherein: the communication interface comprises an RS485 interface and an Ethernet interface.
3. An intelligent powder spray line according to claim 2, wherein: a temperature sensor is arranged in a water tank of the hot water washing bin, and a pressure sensor is arranged on the spraying pipeline;
temperature sensors, free alkalinity sensors and medicament quantity sensors are arranged in the water tanks of the pre-degreasing bin and the degreasing bin, and pressure sensors are arranged on the spraying pipelines;
pH sensors are arranged in water tanks of the pure water washing bin and each level of water washing bin, and pressure sensors are arranged on spraying pipelines;
a conductivity sensor is also arranged in the water tank of the pure water washing bin;
a pH sensor, a temperature sensor, a conductivity sensor and a medicament quantity sensor are arranged in a water tank of the silane spraying bin, and a pressure sensor is arranged on a spraying pipeline;
the temperature sensor, the combustible gas concentration sensor, the waste gas concentration sensor and the high-temperature dust sensor are arranged in the oven of the drying bin and the curing bin, and a gas quantity sensor is arranged on a gas pipeline of the oven;
a face recognition sensor and a camera are arranged at the inlet of the powder spraying chamber, an electrostatic value sensor, a grounding resistance sensor, a humidity sensor, a temperature sensor, a dust concentration sensor and an infrared flame detector are arranged in the powder spraying chamber, a powder flow sensor and a compressed air quantity sensor are arranged on a powder gun of the spraying reciprocating machine, and an atomization pressure detector is arranged on an atomization pipeline of the spraying reciprocating machine;
each sensor, each detector and camera are connected with the monitoring host through RS485 interfaces, and the monitoring host is connected with the storage, the display, the alarm and the cloud software through the wireless communication module.
4. An intelligent powder spray line according to claim 2, wherein: the production line PLC is connected with the water pump in the overhead conveyer and the medicament jar, the combustor and the fan of water purification machine, oven, spraying reciprocating engine, humidifier respectively, is provided with medicament pipeline solenoid valve on the pipeline between medicament jar and the water tank, the multiunit medicament pipeline solenoid valve is connected with production line PLC respectively, and production line PLC passes through the ethernet interface and is connected with the monitoring host computer.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114011635A (en) * | 2021-11-30 | 2022-02-08 | 中国铁建重工集团股份有限公司 | Coating powder spraying line |
| CN115445813A (en) * | 2022-09-29 | 2022-12-09 | 安徽柳溪智能装备有限公司 | Automatic detection and control system for powder spraying film thickness of computer case |
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2020
- 2020-04-13 CN CN202020537311.2U patent/CN211403226U/en active Active
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114011635A (en) * | 2021-11-30 | 2022-02-08 | 中国铁建重工集团股份有限公司 | Coating powder spraying line |
| CN115445813A (en) * | 2022-09-29 | 2022-12-09 | 安徽柳溪智能装备有限公司 | Automatic detection and control system for powder spraying film thickness of computer case |
| WO2024066905A1 (en) * | 2022-09-29 | 2024-04-04 | 安徽柳溪智能装备有限公司 | Automatic measurement and control system for thickness of powder-spraying film of computer case |
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