KR102656893B1 - Industrial smart sensor device and monitoring system using the same - Google Patents

Abstract

The industrial smart sensor device includes a catalytic combustion gas sensor that detects combustible gas, a first minimum detection voltage value of the catalytic combustion gas sensor during a first section, and a second section after the first section. It is characterized by comprising a correction unit that corrects the detection voltage value of the catalytic combustion type gas sensor based on the difference between the second minimum value of the detection voltage value of the catalytic combustion type gas sensor.

Description

Industrial smart sensor device and monitoring system using the same {Industrial smart sensor device and monitoring system using the same}

The present invention relates to an industrial sensor device, and more specifically, to an industrial smart sensor device and a monitoring system using the same.

In order to increase the productivity and quality of products, unnecessary waste factors that occur during production and manufacturing of products, for example, waste factors due to diversification of production items, waste factors due to differences in individual ability of workers, and waste factors due to differences in performance of each machine facility, It is very important to find and eliminate waste factors, waste factors due to differences in work methods, waste factors due to supply disruptions of raw materials/auxiliary materials, etc., and improve the work process based on this.

However, the conventional technology only computerizes various processes within a company and automates the production of products, but has a problem in that it cannot find or remove various waste elements that occur during production and manufacturing of products.

Ultimately, since various waste elements cannot be removed, there is a problem in that there is a limit to improving the productivity and quality of the product.

Regarding the above limitations, it can be seen that productivity improves when changes in the production environment, i.e., facility capacity, worker capacity, etc., are continuously managed.

A smart factory can refer to a factory where the entire product production process is connected through wireless communication and performed automatically.

We improve productivity, quality, and customer satisfaction by applying information and communication technology (ICT) combined with digital automation solutions to production processes such as safety, design, development, manufacturing and distribution, and logistics.

In addition, the Internet of Things (IoT) is installed in facilities and machines within the factory, allowing process data to be collected in real time and decisions based on data to be made, thereby maximizing productivity.

Smart factories are considered a core manufacturing technology of the 4th Industrial Revolution. While the core of the previous manufacturing industry was automated production using PLC, the core of a smart factory is an artificially intelligent process that combines ICT technology with existing production technology.

Recently, as interest has focused on smart factories, research on smart factories is being actively conducted at research institutes and companies around the world.

In particular, in order to build a 4G/5G+WAN to Wi-Fi (802.11AX) CPE-based smart factory system, various sensors must be deployed to detect the environment within the factory and managed efficiently.

KR 10-2199321 B

The present invention was proposed to solve the above technical problems, and provides an industrial smart sensor device that can improve management efficiency by determining the lifespan of the sensor and a monitoring system using the same.

According to an embodiment of the present invention to solve the above problem, a catalytic combustion gas sensor for detecting combustible gas, a first minimum detection voltage value of the catalytic combustion gas sensor during a first section, and the first minimum value of the detection voltage value of the catalytic combustion gas sensor during a first section, An industrial smart sensor device including a correction unit that corrects the detection voltage value of the catalytic combustion type gas sensor based on the difference between the second minimum value of the detection voltage value of the catalytic combustion type gas sensor during the second section after section 1. provided.

In addition, the present invention further includes a determination unit that determines the lifespan of the catalytic combustion gas sensor based on the final detection voltage value output from the correction unit.

In addition, according to another embodiment of the present invention, the catalytic combustion gas sensor detects combustible gas and the catalytic combustion gas sensor based on the difference between the minimum values of the detection voltage values of the catalytic combustion gas sensor during a plurality of sections. An industrial smart sensor device is provided, including a correction unit that corrects the detection voltage value of the sensor, and a determination unit that determines the lifespan of the catalytic combustion gas sensor based on the final detection voltage value output from the correction unit.

In addition, the correction unit included in the present invention includes a first minimum value of the detection voltage value of the catalytic combustion type gas sensor during the first section, and a first minimum value of the detection voltage value of the catalytic combustion type gas sensor during the second section after the first section. The difference between the second minimum value of the detected voltage value is used as a correction value.

Additionally, a monitoring system is provided that includes an industrial smart sensor device and a monitoring unit that receives and manages detection values from the industrial smart sensor device.

The industrial smart sensor device and the monitoring system using the same according to an embodiment of the present invention can build a factory without ICT at the level of automatic aggregation of facility data and real-time decision-making for factory operation, and can create a single product line of wireless sensor devices. It can be expanded and applied to other industrial areas other than smart factories, such as home use and portable use.

In addition, industrial smart sensor devices are deployed in small and medium-sized manufacturing plants to manage the work environment of workers and maintenance of manufacturing facilities, and the proposed industrial smart sensor device and monitoring system using it can determine the lifespan of these sensor devices, thereby improving management convenience. and efficiency is improved.

1 is a configuration diagram of a monitoring system 1 according to an embodiment of the present invention.
Figure 2 is an example diagram of the industrial smart sensor device 100 of the monitoring system 2 of Figure 1
Figure 3 is an example of sensing data being processed in the industrial smart sensor device 100 of Figure 2.
Figure 4 is a diagram showing the operation method of the catalytic combustion gas sensor
Figure 5 is a diagram showing the process of calculating the correction value of the industrial smart sensor device 100.
Figure 6 is a diagram showing the process of determining the lifespan of the industrial smart sensor device 100.

Hereinafter, in order to explain in detail enough to enable those skilled in the art of the present invention to easily implement the technical idea of the present invention, embodiments of the present invention will be described with reference to the accompanying drawings.

1 is a configuration diagram of a monitoring system 1 according to an embodiment of the present invention.

The monitoring system 1 according to this embodiment includes only a brief configuration to clearly explain the technical idea to be proposed.

Referring to FIG. 1, the monitoring system 1 includes a plurality of industrial smart sensor devices 100 and a monitoring unit 200.

The industrial smart sensor device 100 is installed at an industrial site and includes a sensor that detects the environment of the industrial site.

That is, the sensor unit of the industrial smart sensor device 100 includes at least one device capable of detecting carbon monoxide, detecting volatile organic compounds (VOC), detecting combustible gas, detecting photoelectric fire, measuring temperature/humidity, and detecting earthquakes based on a gyro sensor. Equipped with a sensor.

The monitoring unit 200 receives sensing data from a plurality of industrial smart sensor devices 100 wirelessly and then notifies the manager or manages the data by converting it into a database.

FIG. 2 is an exemplary diagram of the industrial smart sensor device 100 of the monitoring system 2 of FIG. 1.

Referring to FIG. 2, the industrial smart sensor device 100 according to an embodiment of the present invention includes a power noise processing unit, an AC/DC converter, a control unit, a real-time operating system, a sensor unit, a speaker, a control button, a memory, and a wireless communication unit. It is composed by:

The power noise processing unit includes a circuit that primarily improves noise generated from AC (alternating current) power. Additionally, the AC/DC converter includes a circuit that converts the alternating current voltage output from the power noise processing unit into direct current voltage (DC).

The control unit includes a microcontroller to control the operation of each component.

The sensor unit is equipped with at least one sensor capable of detecting carbon monoxide, volatile organic compounds (VOC), combustible gas detection, photoelectric fire detection, temperature/humidity measurement, and gyro sensor-based earthquake detection.

The speaker serves to inform information detected by the sensor unit, and the control button performs Wi-Fi connection, regular inspection, and fire alarm stop functions.

The memory stores the measured sensor data for a certain period of time and the alarm sound output through the speaker.

The wireless communication unit includes a Wi-Fi PHY driver unit of 802.11b,g,n standards.

The real-time operating system supports real-time processing of each function by controlling the operation of the sensor unit, speaker, control button, memory, and wireless communication unit.

FIG. 3 is an example of sensing data being processed through an operating system in the industrial smart sensor device 100 of FIG. 2.

Referring to Figure 3, the collected data is expressed as sensor data on the web in conjunction with a monitoring web application.

Sensor data is collected in a NOSQL-based database by converting device id, sensor, sensor value, measurement time, etc. into XML or JSON format. Data received from the sensor device is sensor RAW data received through TCP socket communication or HTTP using REST API.

Figure 4 is a diagram showing the operation method of the catalytic combustion gas sensor.

Referring to FIG. 4, when the industrial smart sensor device 100 is equipped with a catalytic combustion gas sensor, there is a limit to the lifespan due to deterioration due to the operating method characteristics of the catalytic combustion gas sensor.

In other words, the catalytic combustion gas sensor is a type in which a catalyst is coated on a platinum coil, and platinum, palladium, or a mixture is used as the catalyst, and the sensor surface has many pores by increasing the surface area as much as possible to increase the adsorption efficiency of the target gas. It has a processed shape. When the rated voltage is applied to the sensor, the surface temperature is maintained at 200 to 400 degrees Celsius, maintaining a constant resistance. When the gas adsorbed on the surface burns, the resistance increases due to the heat of combustion, and the output voltage increases due to the increase in resistance. Convert.

The output voltage has a linear section and a saturated section, and the zero point may be different for each sensor. These catalytic combustion gas sensors are widely used from industrial sites containing harmful gases to ordinary homes, and are indispensable for protecting the user's life and property by detecting toxic gases and combustible gases in advance and issuing an alarm. This is an important safety device that should not be used.

Figure 5 is a diagram showing the process of calculating the correction value of the industrial smart sensor device 100.

Referring to FIG. 5, a process in which the correction unit calculates a correction value in the industrial smart sensor device 100 equipped with a catalytic combustion gas sensor for detecting combustible gas is shown.

That is, the correction unit determines the first minimum value (MIN1) of the detection voltage value of the catalytic combustion gas sensor during the first section (P1) and the catalytic combustion gas sensor during the second section (P2) after the first section (P1). The difference value (△V) between the second minimum value (MIN2) of the sensor's detection voltage value is used as a correction value.

At this time, only when the minimum value (MIN2) during the second section (P2) increases compared to the minimum value (MIN1) during the first section (P1), the difference between the minimum values (MIN2-MIN1 = △V) is used as the correction value. do.

That is, since the minimum value (MIN3) during the third section (P3) is lower than the minimum value (MIN2) during the second section (P2), this case is not used as a correction value.

Additionally, after the correction value is calculated, the correction value (△V) increases with time and does not decrease. In other words, even when no gas is detected due to sensor deterioration, the output voltage output from the sensor increases in proportion to the deterioration state. Therefore, by reflecting the calculated correction value in the threshold value (alarm value) and raising the threshold value, malfunctions due to deterioration can be prevented. In other words, if the correction value is not reflected, the output voltage output from the sensor continues to rise due to deterioration and reaches the threshold value, causing an error in which an alarm is output even in the absence of gas.

In this way, the correction unit determines the first minimum value of the detection voltage value of the catalytic combustion type gas sensor during the first section and the second minimum value of the detection voltage value of the catalytic combustion type gas sensor during the second section after the first section. Based on the difference value, the detection voltage value of the contact combustion gas sensor can be corrected.

That is, the correction unit can prevent malfunction by correcting the detection voltage value of the contact combustion type gas sensor based on the difference between the minimum values of the detection voltage value of the contact combustion type gas sensor during a plurality of sections.

Figure 6 is a diagram showing the process of determining the lifespan of the industrial smart sensor device 100.

Referring to FIG. 6, the determination unit of the industrial smart sensor device 100 can determine the lifespan of the catalytic combustion gas sensor based on the final detection voltage value output from the correction unit.

Even if the threshold value (alarm value) for determining whether or not there is an alarm continues to rise due to the correction value, it cannot exceed the supplied power voltage (VDD), so the judgment unit determines that the threshold value (alarm value) reaches the power supply voltage (VDD). In this case, it is determined that the life of the sensor has ended.

Meanwhile, it is assumed that a plurality of industrial smart sensor devices 100 are installed diagonally in a rectangular workplace in the plan view, and that each of the industrial smart sensor devices 100 is equipped with a carbon monoxide sensor and a human body detection sensor.

In this way, the first industrial smart sensor device and the second industrial smart sensor device face each other and perform an operation of overlappingly detecting a preset area,

Sensing data from the first industrial smart sensor device is automatically transmitted to the data processing unit that controls the second industrial smart sensor device, and detection data from the second industrial smart sensor device is automatically transmitted to the data processing unit that controls the first industrial smart sensor device. is passed on.

Therefore, when one human body detection sensor detects a human body, the other human body detection sensor automatically detects the human body again.

In particular, the human body detection sensor of the first industrial smart sensor device and the human body detection sensor of the second industrial smart sensor device may be configured to detect internal movement using the Doppler effect.

In other words, the monitoring unit of the proposed system collects information from both sensors, the human body detection sensor of the first industrial smart sensor device and the human body detection sensor of the second industrial smart sensor device, and only detects a person inside when movement is detected at the same time. Determine that it is located.

That is, the motion detection sensor is configured to detect movement using the Doppler effect. Using an ultra-high frequency signal of 10.525 GHz, it accurately and reliably detects the slightest movement of a target regardless of the external environment such as temperature, humidity, and dust. Additionally, the motion detection sensor is configured to adjust the detection distance by adjusting the frequency or output power. It is preferable that the human body detection sensor of the first industrial smart sensor device and the human body detection sensor of the second industrial smart sensor device are set to use different frequencies.

The human body detection sensor of the present invention can be configured to detect movement using the Doppler effect, and uses an ultra-high frequency signal of 10.525 GHz to accurately and reliably detect the slight movement of a target regardless of external environment such as temperature, humidity, and dust. do. In addition, the human body detection sensor is configured to adjust the detection distance by adjusting the frequency or output power.

For reference, if the carbon monoxide sensor of an industrial smart sensor device is installed in the workplace,

The industrial smart sensor device is further equipped with a directional microphone, and the industrial smart sensor device can be controlled to operate for a certain period of time only when noise from a workplace device (carbon monoxide-generating device) is detected.

Additionally, the first warning reference value and the second warning reference value may be automatically adjusted based on atmospheric pressure information among the weather information provided from the monitoring unit. That is, in a state where the surrounding environment is low pressure, the first and second warning reference values for carbon monoxide (which are greater than the first warning reference value) may be automatically increased. That is, the first warning reference value and the second warning reference value may be automatically increased in proportion to the low pressure level.

The industrial smart sensor device and the monitoring system using the same according to an embodiment of the present invention can build a factory without ICT at the level of automatic aggregation of facility data and real-time decision-making for factory operation, and can create a single product line of wireless sensor devices. It can be expanded and applied to other industrial areas other than smart factories, such as home use and portable use.

In small and medium-sized manufacturing plants, industrial smart sensor devices are deployed to manage the work environment of workers and maintenance of manufacturing facilities. The proposed industrial smart sensor device and monitoring system using it can determine the lifespan of these sensor devices, thereby improving management convenience and efficiency. This improves.

As such, a person skilled in the art to which the present invention pertains will understand that the present invention can be implemented in other specific forms without changing its technical idea or essential features. Therefore, the embodiments described above should be understood in all respects as illustrative and not restrictive. The scope of the present invention is indicated by the claims described below rather than the detailed description above, and all changes or modified forms derived from the meaning and scope of the claims and their equivalent concepts should be interpreted as being included in the scope of the present invention. do.

100: Industrial smart sensor device
200: monitoring unit

Claims (5)

delete delete Contact combustion gas sensor that detects combustible gas; A correction unit that corrects the detection voltage value of the catalytic combustion type gas sensor based on the difference between the minimum values of the detection voltage value of the catalytic combustion type gas sensor during a plurality of sections; And a determination unit for determining the lifespan of the catalytic combustion gas sensor based on the final detection voltage value output from the correction unit, wherein the correction unit determines the detection voltage value of the catalytic combustion gas sensor during the plurality of sections. A plurality of industrial smart sensor devices characterized in that they are judged as valid only when the minimum values of gradually increase for each section; and
It includes a monitoring unit that receives and manages the detection values of the plurality of industrial smart sensor devices,
The plurality of industrial smart sensor devices are each equipped with a carbon monoxide sensor and a human body detection sensor, and are installed diagonally in the workplace to repeatedly detect a preset area,
A monitoring system characterized in that the monitoring unit determines that a person is located only when movement is simultaneously detected by industrial smart sensor devices installed diagonally from each other.
According to paragraph 3,
The correction unit,
The difference between the first minimum value of the detection voltage value of the catalytic combustion type gas sensor during the first section and the second minimum value of the detection voltage value of the catalytic combustion type gas sensor during the second section after the first section A monitoring system characterized by using it as a correction value. delete