CN115535571B - Intelligent monitoring system and method for conveying equipment - Google Patents
Intelligent monitoring system and method for conveying equipment Download PDFInfo
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- CN115535571B CN115535571B CN202211156367.3A CN202211156367A CN115535571B CN 115535571 B CN115535571 B CN 115535571B CN 202211156367 A CN202211156367 A CN 202211156367A CN 115535571 B CN115535571 B CN 115535571B
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 80
- 238000000034 method Methods 0.000 title claims abstract description 33
- 230000002159 abnormal effect Effects 0.000 claims abstract description 70
- 239000000463 material Substances 0.000 claims abstract description 54
- 238000007689 inspection Methods 0.000 claims abstract description 53
- 238000001931 thermography Methods 0.000 claims abstract description 48
- 230000005856 abnormality Effects 0.000 claims abstract description 35
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/16—Measuring arrangements characterised by the use of optical techniques for measuring the deformation in a solid, e.g. optical strain gauge
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
- G01J5/48—Thermography; Techniques using wholly visual means
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
- G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
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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
- G05B19/054—Input/output
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Abstract
The invention provides an intelligent monitoring system and method for conveying equipment, wherein the system comprises the following components: the running state acquisition module is used for acquiring running state data of the conveying driving equipment; the 5G video acquisition module is used for acquiring video information of the conveying equipment; the 5G infrared thermal imaging module is used for collecting temperature information of conveyed materials in a segmented mode; the line inspection robot module is used for processing abnormality and feeding back video information according to the instruction of the automatic control module; the main identification controller module is used for identifying video data and thermal imaging data; the automatic control module is used for outputting instructions to the conveying equipment and the line inspection robot through an internal algorithm according to the acquired data and the identification result; the upper computer monitoring module is used for displaying monitoring data, abnormal information, health status, energy consumption and the like of the conveying equipment in real time. By the aid of the scheme, the running state of the conveying equipment can be monitored in real time, abnormal points can be found timely, the abnormality can be treated timely, energy loss is reduced, and production safety is guaranteed.
Description
Technical Field
The invention belongs to the technical field of industrial automation, and particularly relates to an intelligent monitoring system and method for conveying equipment.
Background
The production safety, production efficiency, energy efficiency and the like are very important for general production enterprises, the running state of production equipment and monitoring thereof are closely related to production continuity, production saturation, equipment running efficiency and the like, and the whole production safety and efficiency of the enterprises can be directly influenced. The material conveying equipment is key production equipment of enterprises, is not listed in the range of large-scale key equipment because of low power, and is generally monitored by electric protection of a foundation and manual regular inspection, and is difficult to discover equipment hidden danger and energy waste phenomena due to insufficient monitoring information, so that failure discovery and treatment are not timely, secondary failure loss is easily caused due to serious hysteresis, and meanwhile, the conveying equipment has a severe running environment and serious potential safety hazard to inspection personnel.
Disclosure of Invention
In view of the above, the embodiment of the invention provides an intelligent monitoring system and method for conveying equipment, which are used for solving the problems that failure discovery and treatment are not timely caused by insufficient detection information of the conveying equipment, the running environment of the conveying equipment is bad, and serious potential safety hazards exist for inspection personnel.
In a first aspect of the embodiment of the invention, an intelligent monitoring system for conveying equipment is provided, which at least comprises conveying driving equipment, an operation state acquisition module, a 5G video acquisition module, a 5G infrared thermal imaging module, a main identification controller module, a line inspection robot module, an automatic control module and an upper computer monitoring module;
the running state acquisition module is arranged at a measuring position required by the conveying driving equipment and is used for acquiring running state data of the conveying driving equipment;
the 5G video acquisition module is used for acquiring material video information conveyed by the conveying equipment, deformation deflection video information of the conveying equipment and tearing and breaking hidden danger video information of the conveying equipment, and transmitting the acquired video information to the main identification controller module;
the 5G infrared thermal imaging module is used for collecting temperature information of conveyed materials in a segmented mode and transmitting the thermal imaging temperature information to the main identification controller module;
the line inspection robot module is used for receiving the instruction of the automatic control module, locating abnormal points through the 5G high-speed camera, processing the abnormality through the manipulator and transmitting video information acquired by the 5G high-speed camera in real time to the main identification controller module;
the main identification controller module is used for identifying material video information of the conveying equipment, deformation deflection of the conveying equipment and hidden danger of tearing and breaking of the conveying equipment;
The automatic control module comprises a speed regulation driving device of the conveying driving device, a main control PLC and a communication unit, wherein the speed regulation driving device is used for driving the conveying device, the main control PLC is used for receiving signals of the running state acquisition module and the main identification controller module, outputting instructions to the conveying driving device and the line inspection robot through an internal logic algorithm, and the communication unit is used for communicating with the line inspection robot module and the upper computer monitoring module;
The upper computer monitoring module is used for displaying running state data of the conveying driving equipment, instructions issued by the automatic control module, video information and abnormal points acquired by the 5G high-speed camera, temperature information and abnormal points of thermal imaging conveying materials, safe health state of the conveying equipment, energy consumption of the conveying equipment and electricity unit consumption in real time.
In a second aspect of the embodiment of the present invention, there is provided a method for intelligently monitoring a conveying apparatus, including:
Respectively acquiring operation state data of the conveying driving equipment, video information of the conveying equipment and thermal imaging information of the conveying equipment;
identifying material video information of the conveying equipment, deformation deflection of the conveying equipment and hidden danger of tearing and breaking of the conveying equipment based on the video data and the thermal imaging data;
When abnormal information of materials on the conveying equipment or the conveying equipment is detected, the abnormal information is fed back to the main control PLC, and the main control PLC outputs control instructions to the conveying driving equipment and the line inspection robot according to the abnormal information;
the line inspection robot receives an instruction issued by the main control PLC, positions an abnormal point based on the 5G high-speed camera, processes the abnormality through the manipulator, and acquires video information in real time;
The upper computer displays running state data of the conveying driving equipment, instructions issued by the main control PLC, video information and abnormal points collected by the 5G high-speed camera, temperature information and abnormal points of the thermal imaging conveying materials, safety health state of the conveying equipment, energy consumption of the conveying equipment and electricity unit consumption in real time.
In the embodiment of the invention, the operation parameters of the conveying equipment are acquired, the video and thermal imaging information of the conveying equipment and conveyed materials are identified through main identification control, and the automatic controller is used for controlling, so that the state of the conveying equipment, the energy consumption of the equipment and the like can be monitored, the abnormality of the conveying equipment or the conveyed materials can be timely detected, the resource waste and the potential safety hazard are avoided, the abnormality is processed through the inspection robot, the equipment safety, the production safety and the safety of inspection personnel can be ensured, the energy utilization rate is effectively improved, and the unnecessary manpower and material consumption is reduced.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following description will briefly explain the drawings used in the embodiments or the description of the prior art, and it is obvious that the drawings described below are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort to a person skilled in the art.
Fig. 1 is a schematic structural diagram of an intelligent monitoring system for a conveying device according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating the operation of a master identification controller module according to an embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating an operation principle of an automatic control module according to an embodiment of the present invention;
fig. 4 is a schematic flow chart of a method for intelligently monitoring a conveying device according to an embodiment of the present invention.
Detailed Description
In order to make the objects, features and advantages of the present invention more comprehensible, the technical solutions in the embodiments of the present invention are described in detail below with reference to the accompanying drawings, and it is apparent that the embodiments described below are only some embodiments of the present invention, but not all embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be understood that the term "comprising" and other similar meaning in the description of the invention or the claims and the above-mentioned figures is intended to cover a non-exclusive inclusion, such as a process, method or system, apparatus comprising a series of steps or elements, without limitation to the listed steps or elements. Furthermore, "first" and "second" are used to distinguish between different objects and are not used to describe a particular order.
Referring to fig. 1, a schematic system structure of an intelligent monitoring system for a conveying device according to an embodiment of the present invention includes a conveying driving device 110, an operating state acquisition module 120, a 5G video acquisition module 130, a 5G infrared thermal imaging module 140, a line inspection robot module 150, a main identification controller module 160, an automation control module 170, and an upper computer monitoring module 180;
the operation state acquisition module 120 is disposed at a measurement position required by the conveying driving device 110, and is configured to acquire operation state data of the conveying driving device;
In some embodiments, the operation state collection module 120 includes at least a smart meter for collecting a three-phase circuit, voltage, power, and power consumption of the operation of the conveying driving device, and a vibration sensor for collecting an amplitude and a frequency of the operation of the conveying driving device.
The 5G video acquisition module 130 is configured to acquire video information of a material conveyed by the conveying device, video information of deformation deflection of the conveying device, and video information of hidden danger of tearing and breaking of the conveying device, and transmit the acquired video information to the main identification controller module;
The 5G video acquisition module comprises a 5G high-speed camera and is used for acquiring video data such as materials on conveying equipment, deformation deflection, tearing and breaking of the conveying equipment and the like so as to be identified through the main identification controller module.
The 5G infrared thermal imaging module 140 is used for collecting temperature information of conveyed materials in a segmented mode and transmitting the thermal imaging temperature information to the main identification controller module;
The 5G infrared thermal imaging module comprises a 5G infrared thermal imaging machine and is used for collecting temperature information of conveyed materials in a segmented mode so as to be identified through the main identification controller module.
The inspection robot module 150 is configured to receive an instruction of the automation control module, locate an abnormal point by using the 5G high-speed camera, process the abnormality by using the manipulator, and transmit video information collected in real time by using the 5G high-speed camera to the main recognition controller module;
The line inspection robot can comprise a 5G high-speed camera, a mechanical arm and a communication unit, wherein the 5G high-speed camera is used for collecting abnormal point video information in a short distance, the mechanical arm is used for processing the abnormality on the conveying equipment, and the communication unit is used for receiving the instruction of the automatic control module and transmitting the collected video information to the main identification controller module.
The main identification controller module 160 is used for identifying material video information of the conveying equipment, deformation deflection of the conveying equipment and hidden danger of tearing and breaking of the conveying equipment;
Based on the collected video data and thermal imaging data, the main identification controller can identify and judge abnormal information by identifying the deformation deflection of conveyed materials and conveying equipment and the like through an AI visual processing technology.
In some embodiments, the main recognition controller module 160 at least comprises an AI intelligent recognition unit and a communication unit, wherein the AI intelligent recognition unit is used for recognizing material video information of the conveying equipment, deformation deflection of the conveying equipment and hidden danger of tearing and breaking of the conveying equipment based on video information collected by the 5G high-speed camera; the communication unit is used for communicating with the automatic control module and the upper computer monitoring module respectively, transmitting the identified abnormal information to the automatic control module and transmitting the video information to the upper computer monitoring module.
The automatic control module 170 comprises a speed regulation driving device of a conveying driving device, a main control PLC and a communication unit, wherein the speed regulation driving device is used for driving the conveying device, the main control PLC is used for receiving signals of the running state acquisition module and the main identification controller module, outputting instructions to the conveying driving device and the line inspection robot through an internal logic algorithm, and the communication unit is used for communicating with the line inspection robot module and the upper computer monitoring module;
The speed regulation driving device can drive the conveying driving device 110 to change the running state, the main control PLC (Programmable Logic Controller) can send control instructions to the conveying driving device and the line inspection robot to execute corresponding operations, and the communication unit integrates multiple protocols such as Modbus-RTU, modbus-TCP, TCP/IP, 5G and the like and is used for communicating with the line inspection robot and the upper computer monitoring module.
The upper computer monitoring module 180 is used for displaying running state data of the conveying driving equipment, instructions issued by the automatic control module, video information and abnormal points acquired by the 5G high-speed camera, temperature information and abnormal points of thermal imaging conveying materials, safe health state of the conveying equipment, energy consumption of the conveying equipment and electricity unit consumption in real time.
In some embodiments, the upper computer monitoring module 180 at least includes a conveying equipment running state real-time monitoring unit, a conveying equipment video monitoring unit, a conveying equipment temperature thermal imaging monitoring unit, a conveying equipment diagnosis unit, and a conveying equipment energy-saving analysis unit;
The real-time monitoring unit for the running state of the conveying equipment is used for displaying three-phase current, line voltage, active power, current day accumulated electricity consumption and current month accumulated electricity consumption of the conveying equipment in real time, and sending an on-off and speed instruction to the speed regulation driving equipment and an action instruction of the line inspection robot;
The video monitoring unit of the conveying equipment is used for displaying video information collected by the 5G height cameras and the line inspection robot which are arranged in each section and intelligently marking abnormal points;
The temperature thermal imaging monitoring unit of the conveying equipment is used for displaying temperature information of conveyed materials in an image form and intelligently marking abnormal points;
The conveying equipment diagnosis unit is used for comprehensively diagnosing and analyzing the safety and health state of the conveying equipment based on the recognized material color and shape, the deformation deflection of the conveying equipment, the tearing and breaking hidden trouble of the conveying equipment, thermal imaging and the running state information of the conveying driving equipment, recording the data and the images of each abnormality to form a daily report and a monthly report of safety and health diagnosis, and carrying out multidimensional statistical analysis at least combining the types, the occurrence time, the number of abnormalities and the duration of the abnormalities;
The energy-saving analysis unit of the conveying equipment is used for analyzing the energy consumption and the electricity unit consumption of the conveying equipment, automatically screening and extracting comparable conditions through a built-in algorithm, comparing energy efficiency differences and outputting an energy efficiency analysis report.
As shown in fig. 1, the operation state acquisition module 120 is disposed at a measurement position required by the conveying driving device 110 and is connected to the conveying driving device 110 through a signal line, and the operation state acquisition module 120 communicates with the master control PLC through RS 485;
the 5G video acquisition module 130 is disposed in the conveying device area, and transmits the video signal to the main recognition controller module 160 through 5G communication;
The 5G infrared thermal imaging module 140 is disposed in the conveying device area, and transmits thermal imaging data to the main recognition controller module 160 through 5G communication;
The inspection robot module 150 is disposed in the conveying equipment area, receives the instruction of the automation control module 170 through 5G communication, and sends the collected video signal to the main identification controller 160;
the main identification controller module 160 is arranged in the main control room and is respectively connected with the automation control module 170 and the upper computer monitoring module 180 through communication cables;
The automation control module 170 is disposed in the main controller room, receives the signal of the main identification controller module 160 through the communication cable, and receives the instruction sent by the upper computer monitoring module 180, so as to control the transmission driving device 110 and the inspection robot module 150;
The upper computer monitoring module 180 is respectively connected with the automation control module 170, the main identification controller 160 and the inspection robot module 150 through communication cables, and communicates based on a TCP/IP protocol.
Preferably, in the main identification controller module, the identifying the material video information of the conveying equipment, the deformation deflection of the conveying equipment and the hidden danger of tearing and breaking of the conveying equipment includes:
Based on the collected video data and thermal imaging data, generating a main identification knowledge base through built-in AI and VI algorithms, and continuously correcting the knowledge base;
To-be-identified video information and thermal imaging data, automatically and intelligently identifying the color, granularity and temperature of materials conveyed on conveying equipment and the deformation deflection of the conveying equipment through AI and VI algorithms;
Automatically comparing the identified material color, granularity, temperature and deformation deflection with a main identification knowledge base through the distance anomaly detection of an LOF anomaly detection algorithm, intelligently judging local anomaly factors in the material color, granularity, temperature and deformation deflection data, and positioning anomaly positions to obtain determined anomaly information;
automatically comparing the uncertain abnormal information with a main identification knowledge base by a membership function method of an FLC fuzzy logic control algorithm, and intelligently marking the abnormal position;
And feeding the abnormal information back to the automatic control module.
Exemplary, as shown in fig. 2, the collected video information and thermal imaging information are input to a central processing unit, a main identification knowledge base is generated through built-in AI and VI algorithms, and the knowledge base is automatically and intelligently corrected in long-term operation; automatically and intelligently identifying the color, granularity and temperature of the conveyed materials on the conveying equipment and the deformation deflection of the conveying equipment through built-in AI and VI algorithms; automatically comparing the distance anomaly detection method with a main recognition knowledge base, intelligently recognizing local anomaly factors of color, granularity, temperature and deformation deflection data, intelligently positioning anomaly positions, and feeding back determined information to a central controller; automatically comparing the uncertain abnormal information with a main recognition knowledge base through a membership function method of an FLC fuzzy logic control algorithm, intelligently marking the abnormal position, and feeding back the information to a central controller; the central controller automatically selects a processing scheme according to the abnormal level, feeds back the processing scheme to the automatic controller, outputs an emergency stop instruction by the high-level abnormality, outputs a speed-down running instruction by the medium-level abnormality, and sends an abnormality signal by the low-level abnormality.
The central processing unit is a processor of a main recognition controller module, the LOF (Local outlier factor) anomaly detection algorithm is an algorithm for judging whether each point p is an anomaly point by comparing the densities of the point p and the neighborhood points of the point p, and the FLC (Fuzzy Logic Controller) fuzzy logic control algorithm is an algorithm for representing a process variable as a program language variable with a limited value and then processing the process variable by means of a series of condition rules.
Further, the main control PLC receives the abnormal information fed back by the main identification controller module, and executes a corresponding control strategy according to the abnormal level;
if the first level is abnormal, an emergency stop instruction is sent to the speed regulation driving device and an alarm signal is sent to the upper computer monitoring module, if the second level is abnormal, a speed reduction operation instruction is sent to the speed regulation driving device and an alarm signal is sent to the upper computer monitoring module, and if the third level is abnormal, an alarm signal is sent to the upper computer monitoring module.
The first level of anomalies may correspond to high level anomalies, the second level of anomalies may correspond to medium level anomalies, and the third level of anomalies may correspond to low level anomalies.
Preferably, as shown in fig. 3, after the automatic control module issues the exception handling instruction, each module unit executes a corresponding control policy according to the exception level:
After receiving the instruction of the master control PLC, the speed regulation driving device automatically outputs a control signal to drive the conveying device to change the running state;
After the upper computer monitoring module receives the abnormality warning signal, an instruction is issued to the master control PLC to drive the inspection robot to process abnormality;
After the line inspection robot receives the instruction of the master control PLC, the abnormal point is automatically positioned through the 5G high-speed camera, the robot is driven to process the abnormality, the video signal collected by the 5G high-speed camera is transmitted to the main identification controller, and the main identification controller transmits the real-time collected frequency signal to the upper computer monitoring module;
The upper computer monitoring module monitors the processing operation of the inspection robot in real time, and issues an instruction to the master control PLC of the automatic control module in the upper computer monitoring module so as to finely adjust the action of the manipulator through manual operation.
In this embodiment, not only can monitor conveying equipment, transport material etc. and acquire data such as equipment running state, energy consumption in real time, but also can in time discover equipment anomaly, can accurately detect and judge the anomaly point through corresponding logic algorithm, conveniently in time handle anomaly through inspection robot to can reduce the consumption of energy, ensure conveying equipment safety and production safety.
Fig. 4 is a schematic flow chart of an intelligent monitoring method for a conveying device according to an embodiment of the present invention, where the method includes:
s401, respectively acquiring operation state data of the conveying driving equipment, video information of the conveying equipment and thermal imaging information of the conveying equipment;
The intelligent electric meter is used for detecting three-phase current, voltage, power and electricity consumption of the operation of the conveying driving equipment, and the vibration sensor is used for detecting the amplitude and frequency of the operation of the conveying driving equipment.
And acquiring video information of materials conveyed by conveying equipment, video information of deformation deflection of the conveying equipment and video information of hidden danger of tearing and breaking of the conveying equipment by using a 5G high-speed camera.
And acquiring temperature information of the conveyed materials in a segmented manner through a 5G infrared thermal imaging machine.
S402, identifying material video information of conveying equipment, deformation deflection of the conveying equipment and hidden danger of tearing and breaking of the conveying equipment based on the video data and the thermal imaging data;
the potential hazards of tearing and breaking of the conveying equipment are intelligently identified through the AI, such as material video information on the conveying equipment, deformation deflection of the conveying equipment and tearing and breaking of the conveying equipment.
S403, when abnormal information of materials on the conveying equipment or the conveying equipment is detected, the abnormal information is fed back to the main control PLC, and the main control PLC outputs control instructions to the conveying driving equipment and the line inspection robot according to the abnormal information;
specifically, the detecting the abnormal information of the material on the conveying equipment or the conveying equipment comprises:
Based on the collected video data and thermal imaging data, generating a main identification knowledge base through built-in AI and VI algorithms, and continuously correcting the knowledge base;
To-be-identified video information and thermal imaging data, automatically and intelligently identifying the color, granularity and temperature of materials conveyed on conveying equipment and the deformation deflection of the conveying equipment through AI and VI algorithms;
Automatically comparing the identified material color, granularity, temperature and deformation deflection with a main identification knowledge base through the distance anomaly detection of an LOF anomaly detection algorithm, intelligently judging local anomaly factors in the material color, granularity, temperature and deformation deflection data, and positioning anomaly positions to obtain determined anomaly information;
automatically comparing the uncertain abnormal information with a main identification knowledge base by a membership function method of an FLC fuzzy logic control algorithm, and intelligently marking the abnormal position;
And feeding the abnormal information back to the master control PLC.
Further, the main control PLC receives the abnormal information fed back by the main identification controller module, and executes a corresponding control strategy according to the abnormal level;
if the first level is abnormal, an emergency stop instruction is sent to the speed regulation driving device and an alarm signal is sent to the upper computer monitoring module, if the second level is abnormal, a speed reduction operation instruction is sent to the speed regulation driving device and an alarm signal is sent to the upper computer monitoring module, and if the third level is abnormal, an alarm signal is sent to the upper computer monitoring module.
Preferably, after receiving the instruction of the master control PLC, the speed regulation driving device automatically outputs a control signal to drive the conveying device to change the running state;
After the upper computer monitoring module receives the abnormality warning signal, an instruction is issued to the master control PLC to drive the inspection robot to process abnormality; after the inspection robot receives the instruction of the master control PLC, the inspection robot performs exception handling.
S404, the line inspection robot receives an instruction issued by the main control PLC, positions an abnormal point based on the 5G high-speed camera, processes the abnormality through the manipulator, and acquires video information in real time;
specifically, after the upper computer monitoring module receives the abnormality warning signal, an instruction is issued to the master control PLC to drive the inspection robot to process abnormality;
After the line inspection robot receives the instruction of the master control PLC, the abnormal point is automatically positioned through the 5G high-speed camera, the robot is driven to process the abnormality, the video signal collected by the 5G high-speed camera is transmitted to the main identification controller, and the main identification controller transmits the real-time collected frequency signal to the upper computer monitoring module;
The upper computer monitoring module monitors the processing operation of the inspection robot in real time, and issues an instruction to the master control PLC of the automatic control module in the upper computer monitoring module so as to finely adjust the action of the manipulator through manual operation.
S405, the upper computer displays running state data of the conveying driving equipment, instructions issued by the main control PLC, video information and abnormal points acquired by the 5G high-speed camera, temperature information and abnormal points of a thermal imaging conveying material, the safe health state of the conveying equipment, the energy consumption of the conveying equipment and the electricity unit consumption in real time.
Specifically, the upper computer at least comprises a conveying equipment running state real-time monitoring unit, a conveying equipment video monitoring unit, a conveying equipment temperature thermal imaging monitoring unit, a conveying equipment diagnosis unit and a conveying equipment energy-saving analysis unit;
The real-time monitoring unit for the running state of the conveying equipment is used for displaying three-phase current, line voltage, active power, current day accumulated electricity consumption and current month accumulated electricity consumption of the conveying equipment in real time, and sending an on-off and speed instruction to the speed regulation driving equipment and an action instruction of the line inspection robot;
The video monitoring unit of the conveying equipment is used for displaying video information collected by the 5G height cameras and the line inspection robot which are arranged in each section and intelligently marking abnormal points;
The temperature thermal imaging monitoring unit of the conveying equipment is used for displaying temperature information of conveyed materials in an image form and intelligently marking abnormal points;
The conveying equipment diagnosis unit is used for comprehensively diagnosing and analyzing the safety and health state of the conveying equipment based on the recognized material color and shape, the deformation deflection of the conveying equipment, the tearing and breaking hidden trouble of the conveying equipment, thermal imaging and the running state information of the conveying driving equipment, recording the data and the images of each abnormality to form a daily report and a monthly report of safety and health diagnosis, and carrying out multidimensional statistical analysis at least combining the types, the occurrence time, the number of abnormalities and the duration of the abnormalities;
The energy-saving analysis unit of the conveying equipment is used for analyzing the energy consumption and the electricity unit consumption of the conveying equipment, automatically screening and extracting comparable conditions through a built-in algorithm, comparing energy efficiency differences and outputting an energy efficiency analysis report.
It should be understood that the sequence number of each step in the above embodiment does not mean the sequence of execution, and the execution sequence of each process should be determined by its function and internal logic, and should not be construed as limiting the implementation process of the embodiment of the present invention.
It will be clearly understood by those skilled in the art that, for convenience and brevity of description, specific working procedures of the above-described methods and steps may refer to corresponding functional modules in the foregoing system embodiments, which are not described herein again.
In the foregoing embodiments, the descriptions of the embodiments are emphasized, and in part, not described or illustrated in any particular embodiment, reference is made to the related descriptions of other embodiments.
The above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (7)
1. The intelligent monitoring system of the conveying equipment is characterized by at least comprising conveying driving equipment, an operating state acquisition module, a 5G video acquisition module, a 5G infrared thermal imaging module, a main identification controller module, a line inspection robot module, an automatic control module and an upper computer monitoring module;
the running state acquisition module is arranged at a measuring position required by the conveying driving equipment and is used for acquiring running state data of the conveying driving equipment;
The intelligent ammeter is used for collecting a three-phase circuit, voltage, power and electricity consumption of the operation of the conveying driving equipment, and the vibration sensor is used for collecting the amplitude and the frequency of the operation of the conveying driving equipment;
the 5G video acquisition module is used for acquiring material video information conveyed by the conveying equipment, deformation deflection video information of the conveying equipment and tearing and breaking hidden danger video information of the conveying equipment, and transmitting the acquired video information to the main identification controller module;
the 5G infrared thermal imaging module is used for collecting temperature information of conveyed materials in a segmented mode and transmitting the thermal imaging temperature information to the main identification controller module;
the line inspection robot module is used for receiving the instruction of the automatic control module, locating abnormal points through the 5G high-speed camera, processing the abnormality through the manipulator and transmitting video information acquired by the 5G high-speed camera in real time to the main identification controller module;
the main identification controller module is used for identifying material video information of the conveying equipment, deformation deflection of the conveying equipment and hidden danger of tearing and breaking of the conveying equipment;
The automatic control module comprises a speed regulation driving device of the conveying driving device, a main control PLC and a communication unit, wherein the speed regulation driving device is used for driving the conveying device, the main control PLC is used for receiving signals of the running state acquisition module and the main identification controller module, outputting instructions to the conveying driving device and the line inspection robot through an internal logic algorithm, and the communication unit is used for communicating with the line inspection robot module and the upper computer monitoring module;
The upper computer monitoring module is used for displaying running state data of the conveying driving equipment, instructions issued by the automatic control module, video information and abnormal points acquired by the 5G high-speed camera, temperature information and abnormal points of a thermal imaging conveying material, safety health state of the conveying equipment, energy consumption of the conveying equipment and electric unit consumption in real time;
The upper computer monitoring module at least comprises a conveying equipment running state real-time monitoring unit, a conveying equipment video monitoring unit, a conveying equipment temperature thermal imaging monitoring unit, a conveying equipment diagnosis unit and a conveying equipment energy-saving analysis unit;
The real-time monitoring unit for the running state of the conveying equipment is used for displaying three-phase current, line voltage, active power, current day accumulated electricity consumption and current month accumulated electricity consumption of the conveying equipment in real time, and sending an on-off and speed instruction to the speed regulation driving equipment and an action instruction of the line inspection robot;
The video monitoring unit of the conveying equipment is used for displaying video information collected by the 5G height cameras and the line inspection robot which are arranged in each section and intelligently marking abnormal points;
The temperature thermal imaging monitoring unit of the conveying equipment is used for displaying temperature information of conveyed materials in an image form and intelligently marking abnormal points;
The conveying equipment diagnosis unit is used for comprehensively diagnosing and analyzing the safety and health state of the conveying equipment based on the recognized material color and shape, the deformation deflection of the conveying equipment, the tearing and breaking hidden trouble of the conveying equipment, thermal imaging and the running state information of the conveying driving equipment, recording the data and the images of each abnormality to form a daily report and a monthly report of safety and health diagnosis, and carrying out multidimensional statistical analysis at least combining the types, the occurrence time, the number of abnormalities and the duration of the abnormalities;
The energy-saving analysis unit of the conveying equipment is used for analyzing the energy consumption and the electricity unit consumption of the conveying equipment, automatically screening and extracting comparable conditions through a built-in algorithm, comparing energy efficiency differences and outputting an energy efficiency analysis report.
2. The system according to claim 1, wherein the running state acquisition module is arranged at a measurement position required by the conveying driving equipment and is connected with the conveying driving equipment through a signal wire, and the running state acquisition module is communicated with the master control PLC through an RS 485;
The 5G video acquisition module is arranged in the conveying equipment area and transmits video signals to the main identification controller module through 5G communication;
the 5G infrared thermal imaging module is arranged in the conveying equipment area and transmits thermal imaging data to the main identification controller module through 5G communication;
the main identification controller module is arranged in the main control room and is respectively connected with the automatic control module and the upper computer monitoring module through communication cables;
The line inspection robot module is arranged in the conveying equipment area, receives the instruction of the automatic control module through 5G communication, and sends the collected video signal to the main identification controller;
The automatic control module is arranged in the main controller room, receives signals of the main identification controller module through the communication cable, and receives instructions sent by the upper computer monitoring module so as to control the transmission driving equipment and the line inspection robot module;
the upper computer monitoring module is respectively connected with the automatic control module, the main identification controller and the line inspection robot module through communication cables and is communicated based on TCP/IP protocol.
3. The system according to claim 1, wherein the main recognition controller module at least comprises an AI intelligent recognition unit and a communication unit, wherein the AI intelligent recognition unit is used for recognizing material video information of the conveying equipment, deformation deflection of the conveying equipment and hidden danger of tearing and breaking of the conveying equipment based on video information collected by the 5G high-speed camera;
The communication unit is used for communicating with the automatic control module and the upper computer monitoring module respectively, transmitting the identified abnormal information to the automatic control module and transmitting the video information to the upper computer monitoring module.
4. The system of claim 1, wherein the identifying the material video information of the conveyor apparatus, the deformation deflection of the conveyor apparatus, the tear break hidden danger of the conveyor apparatus comprises:
Based on the collected video data and thermal imaging data, generating a main identification knowledge base through built-in AI and VI algorithms, and continuously correcting the knowledge base;
To-be-identified video information and thermal imaging data, automatically and intelligently identifying the color, granularity and temperature of materials conveyed on conveying equipment and the deformation deflection of the conveying equipment through AI and VI algorithms;
Automatically comparing the identified material color, granularity, temperature and deformation deflection with a main identification knowledge base through the distance anomaly detection of an LOF anomaly detection algorithm, intelligently judging local anomaly factors in the material color, granularity, temperature and deformation deflection data, and positioning anomaly positions to obtain determined anomaly information;
automatically comparing the uncertain abnormal information with a main identification knowledge base by a membership function method of an FLC fuzzy logic control algorithm, and intelligently marking the abnormal position;
And feeding the abnormal information back to the automatic control module.
5. The system of claim 4, wherein the automation control module comprises:
the main control PLC receives the abnormal information fed back by the main identification controller module and executes a corresponding control strategy according to the abnormal level;
if the first level is abnormal, an emergency stop instruction is sent to the speed regulation driving device and an alarm signal is sent to the upper computer monitoring module, if the second level is abnormal, a speed reduction operation instruction is sent to the speed regulation driving device and an alarm signal is sent to the upper computer monitoring module, and if the third level is abnormal, an alarm signal is sent to the upper computer monitoring module.
6. The system of claim 5, wherein the master control PLC receiving the anomaly information fed back by the master recognition controller module, executing the corresponding control strategy according to the anomaly level comprises:
After receiving the instruction of the master control PLC, the speed regulation driving device automatically outputs a control signal to drive the conveying device to change the running state;
After the upper computer monitoring module receives the abnormality warning signal, an instruction is issued to the master control PLC to drive the inspection robot to process abnormality;
After the line inspection robot receives the instruction of the master control PLC, the abnormal point is automatically positioned through the 5G high-speed camera, the robot is driven to process the abnormality, the video signal collected by the 5G high-speed camera is transmitted to the main identification controller module, and the main identification controller module transmits the real-time collected frequency signal to the upper computer monitoring module;
The upper computer monitoring module monitors the processing operation of the inspection robot in real time, and issues an instruction to the master control PLC of the automatic control module in the upper computer monitoring module so as to finely adjust the action of the manipulator through manual operation.
7. A conveying apparatus intelligent monitoring method using the conveying apparatus intelligent monitoring system according to claim 1, characterized by comprising:
Respectively acquiring operation state data of the conveying driving equipment, video information of the conveying equipment and thermal imaging information of the conveying equipment;
identifying material video information of the conveying equipment, deformation deflection of the conveying equipment and hidden danger of tearing and breaking of the conveying equipment based on the video data and the thermal imaging data;
When abnormal information of materials on the conveying equipment or the conveying equipment is detected, the abnormal information is fed back to the main control PLC, and the main control PLC outputs control instructions to the conveying driving equipment and the line inspection robot according to the abnormal information;
the line inspection robot receives an instruction issued by the main control PLC, positions an abnormal point based on the 5G high-speed camera, processes the abnormality through the manipulator, and acquires video information in real time;
The upper computer displays running state data of the conveying driving equipment, instructions issued by the main control PLC, video information and abnormal points collected by the 5G high-speed camera, temperature information and abnormal points of the thermal imaging conveying materials, safety health state of the conveying equipment, energy consumption of the conveying equipment and electricity unit consumption in real time.
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| CN117465950B (en) * | 2023-12-26 | 2024-04-05 | 常州佰承复合材料有限公司 | Nonstandard automation equipment conveying device |
| CN117870779B (en) * | 2024-03-12 | 2024-05-31 | 深圳市广正弘自动化科技有限公司 | Remote wireless intelligent monitoring method and system for automation equipment |
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| CN110589405A (en) * | 2019-09-23 | 2019-12-20 | 北京华方智汇科技有限公司 | Roller abnormity detection system and method for belt conveyor inspection robot |
| CN113682576A (en) * | 2021-08-19 | 2021-11-23 | 红云红河烟草(集团)有限责任公司 | Real-time detection system for walking of synchronous toothed conveying belt of high-speed packaging machine |
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