CN-121995869-A - Calcium carbide method PVC production equipment remote monitoring system and method

CN121995869ACN 121995869 ACN121995869 ACN 121995869ACN-121995869-A

Abstract

The invention relates to the technical field of remote monitoring, in particular to a remote monitoring system and method for calcium carbide PVC production equipment, comprising a data acquisition layer, a data aggregation node, a network transmission layer and a cloud processing layer, wherein the data aggregation node carries out data cleaning and format conversion on signals acquired by all sensors to obtain standardized data to be transmitted, the network transmission layer is connected with the data aggregation node to receive the standardized data to be transmitted, the cloud processing layer is connected with the network transmission layer to receive encrypted data, an equipment operation state association analysis model takes operation parameters of a calcium carbide crusher as a core analysis object, and accurately judges the fault type of the calcium carbide crusher according to a preset fault judgment rule by analyzing the change trend of the two types of parameters and carrying out association operation. The equipment operation state association analysis model of the data analysis module can accurately judge the fault type of the calcium carbide crusher by carrying out association operation on the multi-source data.

Inventors

LI YAWEN
PEI YINGGE
GUO YADONG
LIU YING
YAO WENQIN

Assignees

金川集团股份有限公司
金川集团化工新材料有限责任公司

Dates

Publication Date: 20260508
Application Date: 20251222

Claims (6)

1. The calcium carbide PVC production equipment remote monitoring system is characterized by comprising a data acquisition layer, a data aggregation node, a network transmission layer and a cloud processing layer; The data acquisition layer comprises a vibration sensor and a temperature sensor which are arranged on the calcium carbide crusher, and a pressure sensor and a gas concentration sensor which are arranged on the acetylene generator; The data aggregation node is connected with each sensor of the data acquisition layer, the data aggregation node carries out data cleaning and format conversion on signals acquired by each sensor, the data cleaning is used for removing abnormal interference data, and the format conversion is used for converting heterogeneous data of different types of sensors into a unified standard format to obtain standardized data to be transmitted; The network transmission layer is connected with the data sink node and receives standardized data to be transmitted, is provided with a multi-link redundancy transmission channel, comprises an industrial cellular network channel serving as a main transmission link and a satellite communication channel serving as a standby transmission link, can monitor the signal intensity of the main transmission link in real time, automatically switches a data transmission path to the standby transmission link when the signal intensity of the main transmission link is monitored to be lower than a preset first threshold value, and can automatically switch back to the main transmission link when the signal intensity of the main transmission link is restored to be higher than the first threshold value so as to ensure that the data transmission is not interrupted, and further comprises a VPN encryption module for encrypting the data in the transmission process; The cloud processing layer is connected with the network transmission layer and used for receiving encrypted data, the cloud processing layer comprises a distributed database module and a data analysis module, the distributed database module is used for decrypting the received encrypted data and then storing the decrypted data, the data analysis module is provided with a device operation state association analysis model, the device operation state association analysis model takes operation parameters of the calcium carbide crusher as a core analysis object, and the change trend of the two types of parameters is analyzed and associated operation is carried out by calling vibration amplitude historical data and real-time data collected by a vibration sensor and temperature historical data and real-time data collected by a temperature sensor, wherein the vibration amplitude historical data, the real-time data and the temperature historical data are stored in the distributed database, the fault type of the calcium carbide crusher is accurately judged according to a preset fault judgment rule, and the cloud processing layer further comprises a user interaction module, wherein the user interaction module is in data communication with the data analysis module and the distributed database module and is used for displaying the operation parameters, the fault judgment result and the alarm information push of the device to users.
2. The remote monitoring system of calcium carbide PVC production equipment according to claim 1, wherein the user interaction module comprises a Web terminal and a mobile terminal, and the alarm information is pushed by at least two modes of popup window prompt, short message notification and APP push.
3. The remote monitoring system of calcium carbide PVC production equipment according to claim 1, wherein the industrial cellular network channel adopts an industrial grade 4G or 5G network, and the data aggregation node is internally provided with a signal intensity monitoring chip.
4. The remote monitoring system of calcium carbide PVC production equipment according to claim 1, wherein the distributed database module adopts a storage architecture combining a time sequence database and a relational database, the time sequence database is used for storing time sequence operation data acquired by a sensor in real time, the relational database is used for storing equipment basic information, fault records and user information data, and a multidimensional index strategy of production workshops, equipment types and acquisition time is adopted.
5. The remote monitoring system for calcium carbide PVC production equipment according to claim 1, wherein the equipment operation state association analysis model is obtained by training and optimizing historical operation data and fault case data serving as training sets through a random forest algorithm, and the fault judgment rule comprises the steps of judging that equipment parts are worn and failed when the vibration amplitude exceeds a preset normal range and the temperature is in a continuous rising trend, and judging that foreign matter jam is failed when the vibration amplitude suddenly increases and the temperature does not obviously change.
6. A method for remotely monitoring calcium carbide process PVC production equipment based on the system according to any one of claims 1 to 5, comprising the steps of: The method comprises the steps of S1, installing a vibration sensor and a temperature sensor of a data acquisition layer on a machine body and a motor part of a calcium carbide crusher, installing a pressure sensor and a gas concentration sensor on a reaction cavity and an exhaust port part of an acetylene generator, configuring communication parameters of a data sink node and each sensor, setting a data cleaning rule and a unified standard of format conversion, initializing VPN encryption parameters of a network transmission layer and a first threshold value of main/standby link switching, and completing storage architecture configuration of a cloud processing layer distributed database and deployment of a device running state association analysis model; S2, each sensor of the data acquisition layer acquires the operation parameters of the equipment in real time and transmits the acquired original signals to the data aggregation node, the data aggregation node executes data cleaning according to a preset rule to remove abnormal interference data, and the heterogeneous data are converted into a unified standard format through format conversion to obtain standardized data to be transmitted; S3, the data sink node transmits the standardized data to be transmitted to a network transmission layer, and simultaneously monitors the signal intensity of a main transmission link in real time through a built-in signal intensity monitoring chip; S4, the cloud processing layer receives the encrypted data transmitted by the network transmission layer, decrypts the encrypted data through the distributed database module, stores time sequence operation data according to the time sequence database, stores strategy classification of basic information of the relational database, and establishes indexes through multiple dimensions of production workshops, equipment types and acquisition time; s5, the user interaction module of the cloud processing layer displays the real-time operation parameters of the equipment and the fault judgment result of the data analysis module in a visual mode, and if faults exist or the monitoring parameters exceed the normal range, the alarm information is pushed.

Description

Calcium carbide method PVC production equipment remote monitoring system and method Technical Field The invention relates to the technical field of remote monitoring, in particular to a system and a method for remotely monitoring calcium carbide PVC production equipment. Background Polyvinyl chloride (PVC) is used as an important organic synthetic material and is widely applied to industrial production and daily life, wherein a calcium carbide method is a mainstream process for PVC production in China. The process relates to key equipment such as a calcium carbide crusher and an acetylene generator, and the production environment has the remarkable characteristics of high dust, existence of flammable and explosive gases such as acetylene and the like, and the real-time accurate monitoring of the running state of the equipment is directly related to production safety and efficiency, so that the construction of a reliable monitoring system is important. The traditional monitoring mode of the calcium carbide PVC production equipment mainly depends on a manual inspection or localized DCS/SCADA system, however, the modes have a plurality of defects which are difficult to overcome, wherein the manual inspection is limited by an inspection period, obvious monitoring blind areas exist, continuous monitoring on the running state of the equipment cannot be realized, when the equipment breaks suddenly, quick response is difficult, production interruption and even safety accidents are easy to occur, the localized monitoring system has the problem of data island, monitoring data of all the equipment are stored locally in a scattered manner, data integration analysis of equipment and workshop crossing cannot be realized, remote access and regulation capability are not provided, and the requirement of modern production management on remote management is difficult to meet. With the rise of industrial Internet of things technology, the remote monitoring technology is gradually applied to the field of chemical production, and a new idea is provided for solving the problem of traditional monitoring pain points. For example, chinese patent CN105171748a discloses a method for monitoring the remote status of a robot and a production line device, which adopts a technical architecture of data acquisition, wireless transmission and mobile terminal interaction, and implements remote monitoring of the device to a certain extent by acquiring operation data of the device, transmitting the operation data to a back end for processing via a network, and displaying monitoring information to a user via the mobile terminal. However, when the prior art is applied to the PVC production scene of the calcium carbide method, the prior art still has obvious limitations, the requirements of actual production on the stability, the high efficiency and the accuracy of a monitoring system are difficult to meet, firstly, in terms of data transmission stability, the prior art adopts a wireless transmission mode which lacks redundancy design aiming at complex environments of a chemical industry park, the chemical industry park is often over-heavy in processing load due to geographical positions or the signal shielding effect of large-scale metal equipment, network signals are unstable, once a main transmission link is interrupted, operation data of key equipment such as a calcium carbide crusher, an acetylene generator and the like cannot be transmitted in time, the monitoring data is possibly lost, and the technology is not provided with a standby transmission link based on signal intensity monitoring, the continuity of data transmission cannot be guaranteed, secondly, in terms of data processing and storage, the prior art, the high-frequency data generated by a sensor is huge in terms of data processing and storage, the prior art does not refer to data mechanism at the edge side, the original data is directly transmitted to the rear end, meanwhile, a special storage architecture is not designed aiming at the sensor data with extremely strong time sequence property, the data is difficult to be read and write-in data, finally, in terms of the failure of the prior art, the failure mode is difficult to be directly judged by adopting the prior art, and the failure mode is difficult to be analyzed, and the failure mode is difficult to be directly due to be judged by adopting the failure of the failure mode. Disclosure of Invention Aiming at the problems in the prior art, the invention provides a remote monitoring system and a method for calcium carbide PVC production equipment. In order to achieve the above purpose, the technical scheme of the invention is as follows: A calcium carbide PVC production equipment remote monitoring system comprises a data acquisition layer, a data aggregation node, a network transmission layer and a cloud processing layer; The data acquisition layer comprises a vibration sensor and a temperature sensor which are arranged on the c