CN104793595A - Real-time data acquisition system of wheat processing factory - Google Patents
Real-time data acquisition system of wheat processing factory Download PDFInfo
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- CN104793595A CN104793595A CN201510165593.1A CN201510165593A CN104793595A CN 104793595 A CN104793595 A CN 104793595A CN 201510165593 A CN201510165593 A CN 201510165593A CN 104793595 A CN104793595 A CN 104793595A
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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
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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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
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4183—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by data acquisition, e.g. workpiece identification
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a real-time data acquisition system of a wheat processing factory. Data acquisition work can be carried out on wheat bins, flour bins, equipment and energy consumption and metering units of the wheat processing factory by the real-time data acquisition system, and acquired real-time data can be transmitted into a database server of a data acquisition processing center. Wheat bin and flour bin data acquisition portions comprise temperature, humidity, bin level, weighing and flow wireless sensing nodes, Zigbee terminals and a Zigbee coordinator; PLC (programmable logic controllers) are used as controllers of equipment and energy consumption data acquisition portions. The real-time data acquisition system has the advantages that the relevant data are acquired by temperature, pressure and counting sensor modules and rotational speed and current detecting modules inside the equipment and are transmitted into databases of the server via buses; data portions of the metering unit are acquired by wagon balances and are stored in local databases, and real-time data in the local databases are further transmitted into the server; video monitoring can be carried out on production lines and important places, and accordingly the equipment and the data of various production links can be acquired and analyzed in real time.
Description
Technical field
The present invention relates to a kind of distributed data acquisition system (DAS), specifically a kind of real-time data acquisition system of wheat processing factory.
Background technology
Need through multiple working procedure for the production procedure in wheat processing industry, by raw grain wheat storage, cleaning to flour join powder pack, provide and deliver have the features such as data traffic is large, energy consumption is high, number of devices is numerous and diverse.At existing workshop, production management personnel are carrying out raw grain just clear, grinding screening and are joining in the process of powder packing, and equipment and system are separate work substantially, produce a large amount of equipment and production data is not also used, and production efficiency is lower.
On the other hand, the day by day serious and food processing factory's automatization level of current food-safety problem improves gradually, in order to ensure food security and quality and improve productivity effect, require that production management personnel can analyze equipment a large amount of in production run and production data and be used, effectively can control and failure prediction whole production run.
Summary of the invention
The object of the invention is to solve the information-based not enough present situation of current wheat processing factory, provide a kind of for wheat processing factory real-time data acquisition system, comprehensive utilization several data acquisition mode carries out comprehensive real-time data acquisition.
According to technical scheme provided by the invention, the real-time data acquisition system of described wheat processing factory comprises: wheat bin monitoring means, powder storehouse monitoring means, monitoring of equipment unit, energy consumption monitoring unit, measure monitor unit and data acquisition process center.
Described wheat bin monitoring means and powder storehouse monitoring means comprise the temperature wireless sensing node be located at respectively in wheat bin, powder storehouse, humidity wireless aware node, material level wireless aware node, wireless aware of weighing node, flow wireless aware node, connect respective Zigbee terminal respectively, described Zigbee terminal and Zigbee telegon radio communication, Zigbee telegon connection data acquisition process center; This part is data acquisition.
Described monitoring of equipment unit and energy consumption monitoring unit comprise temperature sensor, count nodes, pressure transducer, ammeter sensing node, bus is connected to respectively by PLC, connect message by bus again to extract and treatment facility, message extraction process equipment connection data acquisition process center; This part is bus data acquisition.
Described measure monitor unit comprises node of weighing, and node of weighing is connected to home server, home server connection data acquisition process center; This part is called data change between database and flash.
Data communication is carried out by various interface and each monitoring means in described data acquisition process center, and the data collected are stored in database server, and carries out feedback and the issue of information by Web server; Data acquisition process center also connects video monitoring system, to plant area, workshop, Office Area, warehouse implementing monitoring, and is exported by field panel and broadcast audio amplifier.
In data acquisition, temperature, humidity, material level, weigh, flow wireless aware node circuit after filtering, digital quantity signal is delivered to described Zigbee terminal, pass through wireless transmission again, received by Zigbee telegon, and be transferred in the oracle database of database server in the heart in data acquisition process by the serial port protocol of setting.
Each Zigbee terminal has been assigned with unique short address and has been distinguished before work, and Zigbee terminal can only communicate with Zigbee telegon, when Zigbee telegon receives the data that each Zigbee terminal sends, an address table is set up in the network address of each Zigbee terminal store, so that database server gathers corresponding sensing data according to address.
In bus data acquisition, described monitoring of equipment unit and energy consumption monitoring unit carry out the monitoring of all devices information and energy consumption in work flow, comprise the state parameter of temperature, counting, pressure, ammeter parameter and equipment self, comprise running state information and the failure message of equipment, the equipment oneself state parameter collected by PLC and sensor information, unified by PROFIBUS-DP bus with the form timed sending of message to data acquisition process center, be deposited in the oracle database of database server by message extraction and treatment facility.
Described measure monitor unit by from node acquired data storage of weighing in the SQL sever database of home server, then by data exchange agreement passage, transfers data in the oracle database of data acquisition process central database server; Editor and the function of document printing of continuous data is realized further by Web server.
The server at data acquisition process center comprises the database server and Web server that are connected to each other, and the information that database server collects carries out feedback and the issue of information by the form of B/S.
Advantage of the present invention is: this system with the server at data acquisition process center for core, the wheat bin monitoring means disperseed, powder storehouse monitoring means, monitoring of equipment unit, measure monitor unit and energy consumption monitoring unit are concentrated and obtains real time data, centralized management, control.Simultaneously, for realizing the visual control to wheat processing factory, add supervisory system, this system comprises the monitoring to plant area, workshop, Office Area, warehouse, supervisory system is connected with data acquisition process center, and exported by field panel and broadcast audio amplifier, ensure whole streamline High-efficient Production and safety.Whole system achieves and utilizes with effective the Real-time Collection of production data in process of factory production; Contribute to realizing carrying out the management and supervision of Life cycle and the strict control to product quality to each equipment, have valuable help to the safe and efficient production of current wheat processing factory.
Accompanying drawing explanation
Fig. 1 is system architecture schematic diagram of the present invention.
Fig. 2 wheat bin, powder storehouse data acquisition structural drawing.
Fig. 3 is bus data acquisition structural representation of the present invention.
Fig. 4 is metering system data exchange structure schematic diagram of the present invention.
Embodiment
Below in conjunction with drawings and Examples, the invention will be further described.
As shown in Figure 1, the present invention includes: wheat bin monitoring means, powder storehouse monitoring means, monitoring of equipment unit, energy consumption monitoring unit and measure monitor unit.Wherein the part of data acquisition of wheat bin, powder storehouse monitoring means comprises the temperature wireless sensing node be located at respectively in wheat bin, powder storehouse, humidity wireless aware node, material level wireless aware node, wireless aware of weighing node, flow wireless aware node, connect respective Zigbee terminal respectively, described Zigbee terminal and Zigbee telegon radio communication, Zigbee telegon connection data acquisition process center, as Fig. 2; This part is data acquisition.Described monitoring of equipment unit and energy consumption monitoring unit comprise temperature sensor, count nodes, pressure transducer, ammeter sensing node, bus is connected to respectively by PLC, connect message by bus again to extract and treatment facility, message extraction process equipment connection data acquisition process center, as Fig. 3; This part is bus data acquisition.Described measure monitor unit comprises node of weighing, and node of weighing is connected to home server, and home server connection data acquisition process center, as Fig. 4; This part is called data change between database and flash.Through the data that data acquisition process center processing is crossed, corresponding data acquisition control order can be sent to the wheat bin monitoring means of dispersion, powder storehouse monitoring means, monitoring of equipment unit, measure monitor unit and energy consumption monitoring unit five parts.In addition, video monitoring is installed to plant area, workshop, Office Area, warehouse, video monitoring system is connected with data acquisition process center, and directly shown by monitoring display screen, supervisory system data feedback after process is to field control center, make corresponding decision, exported by broadcast audio amplifier and on-the-spot LED.
As shown in Figure 2, arrange several temperature, humidity, material level in wheat bin, powder storehouse monitoring means, weigh, flow wireless aware node, the related data collected is sent by Zigbee CC2530 wireless sending module by each node, these terminal nodes have been assigned with unique short address and have been distinguished before work, and Zigbee terminal node can only communicate with Zigbee telegon.When Zigbee telegon receives the data that each terminal node sends, the network address of each terminal node is set up an address table and store, convenient service device gathers the data of respective sensor according to address.Data are sent to server by the final via controller S3C4480 of the real time data that Zigbee telegon receives.Whole process implementation wheat bin, powder storehouse temperature, humidity, material level, to weigh and the real-time data acquisition of flow.
In the present invention, the amount of the data acquisition in wheat bin, powder storehouse is comprised: temperature, humidity, material level, weigh, flow.Temperature Humidity Sensor selects SHT11; Level sensor selects SW-2 stuff level switch; Weigh without sensor selection TSC-2000kG; EDIT solid flowmeter selected by flow sensor; Zigbee CC2530 module selected by wireless transmitter, and microprocessor unit selects S3C4480.The ambient temperature and humidity in wheat bin, powder storehouse detects and arranges 8 Temperature Humidity Sensors altogether, and this Temperature Humidity Sensor SHT11 inside is integrated with filtering and A/D translation function, by digital transfer to Zigbee CC2530 wireless sending module.Meanwhile, wheat bin, powder storehouse arrange 6 level sensors, two LOAD CELLS and two flow sensor nodes respectively.Level sensor is responsible for the concrete position data of monitoring wheat bin wheat, powder storehouse flour; LOAD CELLS is responsible for the general assembly (TW) data acquisition of wheat bin wheat, powder storehouse flour; The data acquisition of wheat bin, powder storehouse turnover flow is responsible for by flow sensor, the real time data collected is sent by Zigbee terminal by all terminal nodes, then Zigbee telegon receives the data passed over, after S3C4480 process, pass to server by RS485 serial ports.In the present embodiment, Zigbee network adopts hub-and-spoke configuration, to its configuration telegon and multiple terminal node, in this Star Network, all terminal nodes all only communicate with telegon, therefore, each terminal node is assigned with a unique address, and telegon is set up address table after receiving the network address and stored, and convenient service device gathers the data of respective sensor according to address.The real-time data acquisition of whole process implementation wheat bin, powder storehouse humiture.
Described monitoring of equipment unit and energy consumption monitoring unit carry out the monitoring of all devices information and energy consumption in work flow, comprise temperature, counting, pressure, the state parameter of ammeter parameter and equipment self, comprise the running state information (device current of equipment, motor speed) and failure message, the equipment oneself state parameter collected by PLC and sensor information, unified by PROFIBUS-DP bus with the form timed sending of message to data acquisition process center, be deposited in the oracle database of database server by message extraction and treatment facility.
In described monitoring of equipment unit and energy consumption monitoring unit, temperature sensor adopts the TTH300 transmitter combination of HD-DS18B20 and ABB AB, count nodes is the inner sensor for countering of baling press, pressure transducer adopts the 261AR baroceptor of ABB AB, and ammeter sensing node is Siemens DTS phase three-wire three intelligent electric meter; PLC adopts the CPU314-DP of SIMATIC S7-300 series, by the data communication form of regulation, information is sent according to the PROFIBUS-DP bus based on RS485, via message extraction and treatment facility, information is stored in database server, described message extracts and treatment facility adopts the PROFICORE equipment of Dutch PROCENTEC company, message extraction and treatment facility by the information that sends over through Serial Port Transmission in database server.Device interior rotating speed, electric current and failure message, by the collection of PLC, are transferred in database server by PROFIBUS-DP and carry out processing and feeding back.In flour processing process, in order to the safety of the quality and equipment that ensure product, monitoring is in real time needed for important production equipment, the power transmission unit such as such as, hoister in production procedure process, auger, scraper plate, blower fan, in real time monitoring is needed for these power transmission unit, the fault in production such as prevent that putty, skidding or pipeline from leaking out; Such as important production equipment, as heavy-duty motors such as dampener, flour mill, high side multideck screens, needs the temperature and the working current that detect its bearing and rotatable parts, prevents equipment from breaking down or maintain in time.Counting unit for monitoring of equipment calculates packing quantity production management personnel can check equipment running status and historical operational information by WEB server, and by analyzing historical failure information, the function such as fault alarm and maintenance prompting can be carried out.The device failure alert information collected by data center and the correlation analysis of product quality, can be improved targetedly to flour production technology.
Energy consumption monitoring aspect, the present embodiment adopts Siemens DTS phase three-wire three intelligent electric meter, for monitoring the energy consumption of each workshop section of production scene and visual plant, for just inventory unit, the mill screen subdivision and join powder packaged unit three workshop sections and be all furnished with an intelligent electric meter of wheat in monitoring of equipment unit, totally 3, workshop section's ammeter, can transmit the energy consumption of three workshop sections.Visual plant is also had also to need energy consumption monitoring unit is installed, the visual plants such as such as flour mill, high pressure positive blower, dampener, totally 20 flour mills, 3 high pressure positive blowers, 2 dampeners, totally 25 autonomous intelligence ammeters, gathered the information of individual equipment energy consumption and workshop section's energy consumption by PLC, via bus transfer in database server, then carried out the statistical study of information by the mode of WEB server.By product quality and workshop section's energy consumption are carried out correlation analysis, can show that energy consumption follows the relation between product quality, as ton powder power consumption important in flour processing form.The failure message of data acquisition process central data consumption information and the collection of monitoring of equipment unit in this invention can carry out correlation analysis, extremely potential potential faults can be predicted, by the irregular operating reminding mainteinance repair to carry out remover apparatus by equipment operation energy consumption.
As shown in Figure 4, measure monitor unit is by the SQL sever database from node of weighing (LOAD CELLS) acquired data storage to home server, again by data exchange agreement passage, transfer data in the oracle database of data acquisition process central database server; Editor and the function of document printing of continuous data is realized further by Web server.
Measure monitor unit for monitoring the information such as the memory space in the purchase volume of raw grain, the inlet amount of workshop, flour outbound amount and warehouse, and by the wheat information that collects to the flour information transmission of output to data acquisition process center.The warehouse-in that goes out in warehouse is monitored in real time, production management personnel can be allowed to understand current inventory status.Meanwhile, the real time data that can be collected by metering system is analyzed production and stock, and draws analysis report.As monitored the wheat information of purchase by metering system, comprise kind, grade, unit price, time etc., then by monitoring the flour that this batch of Wheat Production goes out, can according to the information of flour, comprise flour grade, quality etc., data analysis and process is carried out to flour and wheat, flour extraction can be drawn and can the function such as production capacity and product quality forecast be carried out by data acquisition process center.The measure monitor unit of this example is connected with data acquisition process center, in time the data volume record monitored also is exported the document for printing.
For realizing the visual control to wheat processing factory, the present invention also comprises video monitoring system.Guarded region comprises plant area, workshop, Office Area, warehouse, for monitoring industrial processes and guarantee safety.Supervisory system is connected with data acquisition process center, and is directly shown by display screen, makes corresponding decision, is exported by broadcast audio amplifier and on-the-spot LED.
Based on each detecting unit above-described, in the Flour Producing Line of this example, the overall process that factory dispatches from the factory to flour is entered from raw grain, the full detail of production can be obtained by the server database at data acquisition process center, by the form of WEB server, production management personnel can add up the same day and produce relevant form and data with of that month or certain a collection of wheat flour extraction, the equipment rate of utilization of work hour, power consumption etc.The information at data acquisition process center is transferred to by each production link, set up a data analysis process system in data acquisition process central interior, make it possible to draw by production data scheme improvement production procedure and optimizing product quality being had to directive significance.
Meanwhile, in Flour Producing Line, the equipment of each independent operating in each workshop section, has an automatic control system, can realize decentralised control.Such as in mill screen subdivision, every platform flour mill has oneself a control system, can independent operating under the state of dispersion, and the processing of wheat is a traditional process technique, flow is large, energy consumption is high, equipment is complicated, as disperseed the words of isolated operation, substantially cannot the product of production high-quality, therefore, by the information acquisition of each workshop section's equipment to data acquisition process center, undertaken unifying cooperation control by data acquisition process center.
Simultaneously for the warehouse information that metering system gathers, when assigning production notice for production department, production management personnel can check the raw grain wheat of stock, and estimate to meet order requirements, as do not met the demands, system then can remind production division automatically, and provides difference, then purchasing of raw materials application is submitted to, to ensure delivering goods on schedule of order by production division to purchasing department.
In information acquisition system simultaneously described in this invention, there is the function of data analysis at data acquisition process center, the such as real-time monitoring and control of flour mill electric current, if this continuing current flow rises, be likely then charging too much or grinding roller need the production problems such as replacing, can by the form of WEB server, real-time reminding production management personnel overhaul.The faults such as the status information of equipment and historical information and product quality are analyzed, can draw to improve and monitor the equipment of fault or the process section of Frequent Troubles, thus can the prioritization scheme such as Improving The Quality of Products.
Claims (7)
1. the real-time data acquisition system of wheat processing factory, is characterized in that, comprising: wheat bin monitoring means, powder storehouse monitoring means, monitoring of equipment unit, energy consumption monitoring unit, measure monitor unit and data acquisition process center,
Described wheat bin monitoring means and powder storehouse monitoring means comprise the temperature wireless sensing node be located at respectively in wheat bin, powder storehouse, humidity wireless aware node, material level wireless aware node, wireless aware of weighing node, flow wireless aware node, connect respective Zigbee terminal respectively, described Zigbee terminal and Zigbee telegon radio communication, Zigbee telegon connection data acquisition process center;
Described monitoring of equipment unit and energy consumption monitoring unit comprise temperature sensor, count nodes, pressure transducer, ammeter sensing node, bus is connected to respectively by PLC, connect message by bus again to extract and treatment facility, message extraction process equipment connection data acquisition process center;
Described measure monitor unit comprises node of weighing, and node of weighing is connected to home server, home server connection data acquisition process center;
Data communication is carried out by various interface and each monitoring means in described data acquisition process center, and the data collected are stored in database server, and carries out feedback and the issue of information by Web server; Data acquisition process center also connects video monitoring system, to plant area, workshop, Office Area, warehouse implementing monitoring, and is exported by field panel and broadcast audio amplifier.
2. the real-time data acquisition system of wheat processing factory according to claim 1, it is characterized in that, temperature, humidity, material level, weigh, flow wireless aware node circuit after filtering, digital quantity signal is delivered to described Zigbee terminal, pass through wireless transmission again, received by Zigbee telegon, and be transferred in the oracle database of database server in the heart in data acquisition process by the serial port protocol of setting.
3. the real-time data acquisition system of wheat processing factory according to claim 2, it is characterized in that, each Zigbee terminal has been assigned with unique short address and has been distinguished before work, and Zigbee terminal can only communicate with Zigbee telegon, when Zigbee telegon receives the data that each Zigbee terminal sends, an address table is set up in the network address of each Zigbee terminal store, so that database server gathers corresponding sensing data according to address.
4. the real-time data acquisition system of wheat processing factory according to claim 1, it is characterized in that, described monitoring of equipment unit and energy consumption monitoring unit carry out the monitoring of all devices information and energy consumption in work flow, comprise temperature, counting, pressure, the state parameter of ammeter parameter and equipment self, comprise running state information and the failure message of equipment, the equipment oneself state parameter collected by PLC and sensor information, unified by PROFIBUS-DP bus with the form timed sending of message to data acquisition process center, be deposited in the oracle database of database server by message extraction and treatment facility.
5. the real-time data acquisition system of wheat processing factory according to claim 1, it is characterized in that, described measure monitor unit is by from node acquired data storage of weighing in the SQL sever database of home server, again by data exchange agreement passage, transfer data in the oracle database of data acquisition process central database server; Editor and the function of document printing of continuous data is realized further by Web server.
6. the real-time data acquisition system of wheat processing factory according to claim 1, it is characterized in that, in the bus data acquisition of described monitoring of equipment unit and energy consumption monitoring unit, temperature sensor adopts the TTH300 transmitter combination of HD-DS18B20 and ABB AB, count nodes is the inner sensor for countering of baling press, pressure transducer adopts the 261AR baroceptor of ABB AB, and ammeter sensing node is Siemens DTS phase three-wire three intelligent electric meter; PLC adopts the CPU314-DP of SIMATIC S7-300 series, by the data communication form of regulation, information is sent according to the PROFIBUS-DP bus based on RS485, via message extraction and treatment facility, information is stored in database server, described message extracts and treatment facility adopts the PROFICORE equipment of PROCENTEC company, message extraction and treatment facility by the information that sends over through Serial Port Transmission in database server.
7. the real-time data acquisition system of wheat processing factory according to claim 1, it is characterized in that, the server at data acquisition process center comprises the database server and Web server that are connected to each other, and the information that database server collects carries out feedback and the issue of information by the form of B/S.
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| CN106338960A (en) * | 2016-09-14 | 2017-01-18 | 芜湖扬展新材料科技服务有限公司 | Distributed production workshop intelligence data monitoring transmission apparatus |
| CN107870616A (en) * | 2017-12-26 | 2018-04-03 | 大连翼方科技有限公司 | A kind of integrated control system |
| CN109242346A (en) * | 2018-10-11 | 2019-01-18 | 安徽顶康食品有限公司 | A kind of quality and safety control system suitable for flour processing |
| CN109242346B (en) * | 2018-10-11 | 2022-01-04 | 安徽顶康食品有限公司 | Quality safety control system suitable for flour processing |
| CN110990457A (en) * | 2019-11-30 | 2020-04-10 | 航天科技控股集团股份有限公司 | Production report management system |
| CN111506038A (en) * | 2020-07-01 | 2020-08-07 | 粤海永顺泰(广州)麦芽有限公司 | Malt monitoring and inspection data processing method and system |
| CN111637914A (en) * | 2020-07-06 | 2020-09-08 | 山西省煤炭地质物探测绘院 | Metering data acquisition and analysis control system based on big data analysis method |
| CN111857082A (en) * | 2020-08-14 | 2020-10-30 | 昆山同日工业自动化有限公司 | Intelligent workshop remote diagnosis control system based on 5G network |
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