I. Project background
The original system is installed on more than 20 door machines (door cranes). At present, the weighing data acquisition system (single-chip microcomputer development) has been installed, and the IC card data transmission mode is adopted, which mainly collects the workload of the door operator and collects The data information includes data such as commuting record, number of grabs, weight per time, cumulative weight, and number of overweight alarms. Every time the driver goes to work at the door machine, he inserts an IC card, pulls out the card after work, and sends it to the door machine computer to read the data. The door machine management team is equipped with management software to summarize, analyze and report the job data. However, due to the lack of scientific and rational software components and the seriousness of data collection errors, management software has not played its due role. In addition, the detection of the working state of the door machine is carried out by the inspection personnel on the spot machine on a regular basis, and the working state of the door machine cannot be obtained in real time, so that the door machine can not be repaired in a targeted manner, resulting in waste of manpower and material resources.
The time lag and accuracy of the original system data transmission need to be improved, and the upper computer management software also needs to be updated accordingly to achieve real automatic operation of door machine operation. In addition, for the safety production warning needs, the wind speed alarm device and the door machine working state detection should be installed in the working area of ​​the door machine. The driver can see the wind speed and alarm status in real time, and the real-time wind speed data and the door can be wirelessly The machine working status information is transmitted to the monitoring room, which facilitates the door machine management department to perform job scheduling and equipment maintenance.
In order to realize scientific and convenient management, it is now necessary to transmit the door weighing system, anemometer and door machine working status information data to the door fleet monitoring center in real time to solve the time lag of IC card data transmission mode and strengthen the door machine. The management of the work and the accident prevention ability in the work process. The system adopts the wireless data transmission mode of GPRS to ensure the consistency of the data obtained by the site and the management center. The RTU-2600 intelligent terminal is equipped at the work site to facilitate real-time acquisition. Transmission data; equipped with HMI-3800 man-machine interface for door operator to operate; re-equipped with host computer data management software in the management center, receiving on-site work data, and realize user management, curve display, report printing, historical data recording and other functions.
Second, the demand analysis
1, wind speed
(1) While the driver turns on the power, the wireless terminal transmits the field wind speed data to the monitoring center every 2 minutes. And the real-time wind speed is displayed on the spot through the digital tube display;
(2) When the on-site intelligent terminal detects that the wind speed signal reaches the warning line, it sends an "on" signal to the buzzer alarm device on the site through the switch output interface, and the buzzer alarm device emits an alarm sound, and the "wind speed" on the digital display screen The alarm "red light flashes to alert the driver of the door machine;
(3) After the wind speed data is transmitted to the monitoring center, it is recorded on the wind speed database, and the real-time curve and historical curve of the wind speed can be displayed;
(4) Once the wind speed warning occurs, the software reminds the management personnel to make corresponding measures by means of voice prompts and picture display.
2, weighing
(1), can display and upload weighing data in real time, automatically peeled.
(2), can set and carry out weighing alarm.
3, door machine status detection
(1), the door machine status information can be uploaded periodically or actively, and the status information is taken from the PLC of the door machine control system;
(2) When the door machine fails, it can alarm.
4. On-site intelligent terminal
(1) The user interface is clear, easy to learn, and easy to operate;
(2) The on-site intelligent terminal has an accurate internal clock and calendar;
(3), the driver's commute record;
(4) Record of each picking operation;
(5), set the overweight alarm value, wind speed alarm value, door machine number, driving staff number;
(6), on-site display of door machine operation data;
(7), set the server IP address;
(8), when the wireless network fails, it can send SMS alarm;
5, client software
(1) Database storage and display of weighing data
(2), salary statement;
(3), single ship workload report;
(4), fault report;
(5), real-time and historical wind speed curve display;
(6), user permission settings;
(7), early warning tips;
(8), database query;
(9), printing function
(10) Humanized information management software interface, which is convenient for management personnel to manage and analyze door machine data.
Third, system design
2.1 System composition
According to the project demand situation, the whole system is divided into two parts, one part is to collect the field operation data of the door crane device and automatically carry out the overweight alarm under certain circumstances to prevent the occurrence of production accidents. The job data that needs to be collected are: door number, driver number, cumulative number of grabs, weight of each grab, accumulated weight, number of overweight alarms, real-time wind speed of the working environment, and door machine working status information; Machine, it realizes the information management of data receiving, storage, display and curve display, report printout and other special situation warning.
The on-site information collection and transmission part uses the programmable remote control terminal RTU-2600 of Weikong Technology, and the collected data is transmitted to the server of the door fleet through GPRS in real time. The on-site information display adopts the digital tube display, and the operation man-machine interface uses HMI-3800. The upper computer information management software adopts C/S architecture, the database is written by SQL, the communication machine and the management software are compiled by VB.NET.
2.2, system schematic
2.3 Data transmission method
The collected data collected by the RTU-2600 is directly transmitted to the monitoring center via GPRS.
2.4, system hardware composition and its role
1. Smart wireless remote measurement and control terminal RTU-2600
The RTU-2600 programmable remote measurement and control terminal combines the functions of acquisition, control and communication to realize the collection and transmission of data. It is the front-end core of the whole system. The data is collected by using the switch quantity and analog data acquisition interface that it has, and the data is sent to the remote monitoring center through its own GPRS wireless communication module. Since this intelligent terminal provides a convenient secondary development C language platform, various complex algorithms can be developed and seamlessly connected with the configuration software. Through the programming inside the intelligent terminal, we can process some data transmitted by the sensor and send it to the remote management center, and realize intermittent data transmission to reduce the traffic charge of data transmission.
2. Operation terminal---HMI-3800
3.8-inch blue-white on-line LCD screen display, 8 operating buttons on the panel, you can set the terminal information, such as the monitoring center's IP address, door number, weighing overweight alarm value, wind speed alarm value, etc.; The driver's operation is also carried out on the HMI-3800.
3. Field data display
The digital tube display displays real-time job information and alarm information.
Slight level overweight alarm: The overweight alarm indicator is on and the buzzer alarm is not ringing. The intelligent measurement and control terminal judges that the operation is valid, does not send a closing signal to the load control switch, and the door machine can work normally. At the same time, the driver is prompted to overweight the weight value, and the alarm indicator light is illuminated to remind the driver to work again to prevent overweight.
Forbidden level overweight alarm: The overweight alarm light is on, and the buzzer alarm sounds at the same time. When the load control switch is closed, the door machine stops working. At the same time, the alarm indicator lights up and the buzzer is turned on for 10 seconds to remind the driver that the operation is prohibited. The intelligent measurement and control terminal does not send data back to the monitoring center.
General-level wind speed alarm (>15m/s): The wind speed warning light is on, and the buzzer alarm is not ringing. When the customs>15m/s, the wind speed warning light is on, and the buzzer alarm does not ring, indicating that the driver needs to pay attention to prevent overweight when the wind speed is too large.
The severity wind speed alarm (>17.1m/s) wind speed warning light is on, and the buzzer alarm sounds at the same time. When the wind speed is >17.1m/s, the closing signal is transmitted to the load control switch, the door machine stops working, the wind speed warning light is on, and the buzzer alarm sounds at the same time, prompting the driver that the wind speed is too large to continue the operation, and the operation before the wind speed is reduced It is regarded as invalid, and the monitoring center software performs wind speed alarm, prompting the dispatching squad leader to make corresponding accident prevention measures. After the wind speed reaches the safe working range, the door machine cross-open switch is turned on, and the door machine resumes normal work.
4, the main data acquisition equipment of the door hanging weighing system
(1), weighing sensor, using two BK-1A pull sensor in parallel to collect the weighing signal, can make the weighing signal more accurate, can also play the role of hot standby.
(2), the over-the-shore switch, using two 12V signal over-shore switches, can more accurately calculate the number of operations, can also play the role of hot standby.
(3), anemometer, combined with the actual situation of the port to select mechanical pulse output anemometer, the range is 0-30m / s.
Third, the site operation process
1. The door machine driver goes to work, press the work button (record the working time, the system is time), input the work number (record the driver.
2. The driver starts the operation. The intelligent wireless measurement and control terminal judges whether the job is valid through the weight signal transmitted from the load cell and the signal from the over-the-shore switch. It automatically records the net weight of each job, the number of operations, the net weight accumulation, and sends it to the monitoring. center;
3. During the driver's operation, the intelligent terminal transmits the gross weight data of each operation and the accumulated number of calculated operations to the digital display screen for display;
4. If the cargo in the operation is overweight, the intelligent terminal outputs an alarm signal to the buzzer alarm device for on-site overweight alarm, and the "overweight alarm" on the digital display is red, prompting the on-site staff;
5. If the lifting machine or the door machine needs to be faulty, press the corresponding operation key on the man-machine interface to perform the corresponding operation, and the intelligent terminal will automatically record the operation and upload it to the monitoring center in real time;
6. After the driver completes the shift, press the shift button, and the intelligent terminal transmits the off-duty signal back to the monitoring center. After the monitoring center software receives the off-duty signal, it automatically settles the number of times of the shift, and calculates the net weight of the accumulated operation;
Fourth, door machine information management system client software
4.1 system login
4.2 User Management
4.3 door machine management
4.4 Driver File Management
4.5 Weighing Data Management
4.6 weighing histogram
4.7 Driver Operation Information
4.8 Driver's salary report
4.9 door machine failure report
4.10 wind speed history curve
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