CN114442544A - Industrial equipment intelligent monitoring video acquisition method based on PLC - Google Patents
Industrial equipment intelligent monitoring video acquisition method based on PLC Download PDFInfo
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Abstract
The invention is suitable for the field of computers, and provides an industrial equipment intelligent monitoring video acquisition method based on a PLC (programmable logic controller), which monitors communication signals of all equipment connected with the PLC; the method comprises the steps that state data of each device are obtained regularly through a data acquisition module A and stored in a PLC database; acquiring event occurrence time and equipment information corresponding to the communication signals through the data acquisition module B, and comparing data acquired at different times bit by bit so as to filter out useless data and store the useful data in a database; the data in the database is extracted in a timing mode through the data acquisition module C, and corresponding video recording files stored by the monitoring system are inquired according to the data in the database and the mark structure state generated in the data storage process; and carrying out video recording interception and local storage operation. The method realizes the data cleaning function, and the valuable video images are screened out through the logic of the method to realize the intelligent recording function of the industrial equipment.
Description
Technical Field
The invention belongs to the field of computers, and particularly relates to an intelligent monitoring video acquisition method for industrial equipment based on a PLC.
Background
At present, the equipment based on PLC (programmable logic controller) in the market basically displays abnormal information on HMI (human machine interface) of the equipment in descriptive content, the actual state and action of the equipment can not be captured in the running state, and the functions provided by the traditional monitoring are only recording and uninterruptedly recording pictures according to a picture capturing algorithm and can not be associated with the equipment data.
Disclosure of Invention
The embodiment of the invention provides an industrial equipment intelligent monitoring video acquisition method based on a PLC (programmable logic controller), aiming at solving the problems in the background art.
The embodiment of the invention is realized in such a way that the industrial equipment intelligent monitoring video acquisition method based on PLC comprises the following steps:
monitoring communication signals of each device connected with the PLC;
the method comprises the steps that state data of each device are obtained regularly through a data acquisition module A and stored in a PLC database;
acquiring event occurrence time and equipment information corresponding to the communication signals through the data acquisition module B, and comparing data acquired at different times bit by bit so as to filter out useless data and store the useful data in a database;
the data in the database is extracted in a timing mode through the data acquisition module C, and corresponding video recording files stored by the monitoring system are inquired according to the data in the database and the mark structure state generated in the data storage process;
and finally, video recording interception and local storage operation are carried out.
Further, the obtaining, by the data acquisition module a, the state data of each device at regular time and storing the state data in the PLC database specifically includes:
establishing communication between the PLC and each external device through a standard protocol;
controlling the PLC to access a data storage area of the external equipment;
and defining data stored in the storage area of the external equipment according to the address of the storage area of the external equipment, and regularly storing the required data in a PLC database, thereby supporting data acquisition of the data acquisition module B.
Further, the data acquisition module B directly reads the PLC database, and simultaneously establishes a PLC polling mechanism, writes the polled data into the memory of the data acquisition module B, compares the read data with the data in the memory at the next polling, and completes the data extraction and write-in operations after the comparison.
Further, before monitoring communication signals of each device connected to the PLC, the method further includes:
initializing the communication between each device and the PLC;
the initialization method specifically comprises the following steps:
loading an IP (Internet protocol) address and a port number of the PLC through a configuration document;
configuring TCP (transmission control protocol) communication parameters through a circulation mode, and connecting corresponding PLCs one by one;
judging whether the connection between the PLC and the TCP is successful or not through a handshake signal fed back by the PLC;
multithreading in the module realizes real-time monitoring whether the PLC is normally connected, and if the PLC is failed to be connected, a message is sent to the alarm module so as to trigger alarm processing and related log records;
the program automatically tries to reconnect the PLC communication when disconnection occurs by setting conditions, and simultaneously records the connection times and the disconnection reason according to the conditions.
Further, before monitoring communication signals of each device connected to the PLC, the method further includes:
establishing a mapping relation between the PLC and each equipment database;
the method for establishing the mapping relationship specifically comprises the following steps:
establishing a mapping relation between an absolute address in the PLC and an equipment label by reading an equipment configuration document;
indexing the absolute address of the PLC database through the equipment tag, and establishing a mapping relation with each storage area of the PLC database;
after reading the stored data of the PLC, carrying out data type conversion according to requirements;
and establishing a mapping relation between the converted data and the label through the configuration document.
Further, the establishing a PLC polling mechanism specifically includes:
establishing a mapping relation between the PLC and the workstation through an advanced configuration document;
controlling and polling a database area corresponding to each PLC through the monitoring point number; wherein the polling period can be set through a UI (user interface).
Further, the data extraction and write operation of the data acquisition module B specifically includes:
scanning data in a PLC database in the polling process, and sequentially storing the data in corresponding caches according to monitoring point numbers; wherein the cache access mode adopts a stack mode;
comparing the latest data scanned by current polling with the data in the last cache bit by bit;
in the bit-by-bit comparison, if the bit state is changed from 0 to 1, a new alarm is generated; if the bit state is changed from 1 to 0, ending the current alarm;
when a new alarm is generated, adding an alarm record to the database through the database statement; and when the alarm is finished, updating the finishing time of the original record in the database to form a complete alarm time period.
Further, the extracting, by the data acquisition module C, the data in the database at regular time, and querying the corresponding video recording file stored by the monitoring system according to the data in the database and the flag structure state generated in the data storage process specifically includes:
inquiring the value of the task judgment variable, and judging whether data needing local video storage exists in a database of the data acquisition module B;
if the task judgment variable is equal to 0, the data with the storage completion variable being 0 does not exist in the current database, namely, the data to be effectively stored does not exist, the program will wait for the next query regularly until the task judgment variable is not equal to 0, and the data to be stored appears in the system;
for the task judgment variable, if the data of the row with the storage completion variable being 0 exists in the database table, the task judgment variable is not equal to 0, otherwise, the task judgment variable is equal to 0;
for the storage completion variable, all the 'storage completion variables' of the initial data inserted by the data acquisition module B are 0, the program firstly acquires the time point and the monitoring point data of the data to be stored in the data acquisition module B, assigns the time point and the monitoring point data to the 'effective data time variable' and the 'effective data monitoring point variable', assigns the time point and the 'cache monitoring point variable' simultaneously, judges whether the 'effective data time variable' and the 'effective data monitoring point variable' of the data are the same as the 'cache time variable' and the 'cache monitoring point variable' of the previous data when the program reads the next data, judges that the invalid data do not execute video storage action if the data are the same, and updates the 'storage completion variable' to 1; otherwise, the local video storage action is executed for the effective data, and the storage completion variable is updated to be 1;
the program executing the video storage action judges whether the last storage task is finished or not according to the value of a task completion variable, if the task completion variable is 0, the last storage action is not finished, the program waits for next query until the video storage action is finished, the program changes the task completion variable into 1, and the last video storage action is finished and the next video storage action can be carried out;
the task judgment variable is used for judging whether new video data to be stored exist or not; the task completion variable is used for judging whether the last local storage task is completed; the storage completion variable is used for identifying whether the piece of data is a stored video; the effective data time variable, the effective data monitoring point variable, the cache time variable and the cache monitoring point variable are used for judging whether repeated data to be stored exist.
The invention has the beneficial effects that: the data association between the PLC programming equipment and the monitoring equipment is realized, the data cleaning function is realized, namely valuable video images are screened out through the logic of the method, and the intelligent recording function of industrial equipment is realized. The problem that when abnormal information occurs to the equipment, actual action or state pictures cannot be effectively screened and stored, and therefore the state of the equipment at the time when the problem occurs cannot be researched is solved. The problem that the data of the equipment controlled by the PLC cannot interact with the monitoring equipment is solved essentially, and the intelligent recording function in the industry is realized equivalently through software.
Drawings
FIG. 1 is a schematic flow chart of a PLC-based industrial equipment intelligent monitoring video acquisition method;
FIG. 2 is a schematic diagram of data cleaning of an industrial equipment intelligent monitoring video acquisition method based on PLC;
FIG. 3 is a communication diagram of a PLC-based industrial equipment intelligent monitoring video acquisition method;
FIG. 4 is a diagram of a device structure with PLC in a PLC-based industrial device intelligent monitoring video acquisition method;
FIG. 5 is a detailed flow chart of a data acquisition module A in the PLC-based industrial equipment intelligent monitoring video acquisition method;
FIG. 6 is a detailed flow chart of a data acquisition module B in the PLC-based industrial equipment intelligent monitoring video acquisition method;
FIG. 7 is a detailed flow chart of a data acquisition module C in the PLC-based industrial equipment intelligent monitoring video acquisition method;
fig. 8 is a monitoring system structure diagram in an industrial equipment intelligent monitoring video acquisition method based on PLC.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Fig. 1 is a schematic flowchart illustrating a method for collecting an intelligent monitoring video of an industrial device based on a PLC according to an embodiment of the present invention, where the method for collecting an intelligent monitoring video of an industrial device based on a PLC includes:
step S10: monitoring communication signals of each device connected with the PLC;
step S11: the method comprises the following steps of (1) acquiring state data of each device at regular time (millisecond level) through a data acquisition module A and storing the state data into a PLC database;
step S12: acquiring event occurrence time and equipment information corresponding to the communication signals through the data acquisition module B, and comparing data acquired at different times bit by bit so as to filter out useless data and store the useful data in a database;
step S13: the data in the database is extracted at regular time (second level) through a data acquisition module C, and the corresponding video recording files stored by the monitoring system are inquired according to the data (time points, corresponding monitoring channels and storage marks of the monitoring points) in the database and the mark structure state generated in the data storage process;
step S14: and finally, video recording interception and local storage operation are carried out.
The method adopts various development tools and communication protocols to realize data intercommunication between the equipment with the PLC and the monitoring equipment in different modules (the communication mode is shown in figure 3), thereby realizing data cleaning (shown in figure 2) and intelligent monitoring picture acquisition of the video recorded during the operation of the equipment.
Fig. 5 shows a detailed flowchart of a data acquisition module a in the method for acquiring an intelligent monitoring video of an industrial device based on a PLC according to an embodiment of the present invention, where the data acquisition module a mainly implements a device data acquisition function connected to the PLC. The method for acquiring the state data of each device in a timing manner and storing the state data into the PLC database through the data acquisition module A specifically comprises the following steps:
step S20: communication between the PLC and the external devices (as shown in fig. 4) is established via standard protocols.
Step S21: and controlling the PLC to access a data storage area of the external equipment.
Step S22: and defining data stored in the storage area of the external equipment according to the address of the storage area of the external equipment, and regularly storing the required data in a PLC database, thereby supporting data acquisition of the data acquisition module B.
Fig. 6 shows a detailed flowchart of a data acquisition module B in the PLC-based industrial device intelligent monitoring video acquisition method according to the embodiment of the present invention, where the data acquisition module B directly reads a PLC database, thereby replacing the function of purchasing a third-party commercial OPC interface, and simultaneously establishes a PLC polling mechanism, writes polled data into a memory of the data acquisition module B, compares the read data with data in the memory at the next polling, and completes the data extraction and write-in operations after the comparison.
In one aspect of this embodiment, before monitoring the communication signals of the devices connected to the PLC, the method further includes:
step S30: initializing the communication between each device and the PLC;
step S31: the initialization method specifically comprises the following steps:
step S32: loading the IP address and the port number of the PLC through the configuration document;
step S33: configuring TCP (transmission control protocol) communication parameters through a circulation mode, and connecting corresponding PLCs one by one;
step S34: judging whether the connection between the PLC and the TCP is successful or not through a handshake signal fed back by the PLC;
step S35: multithreading in the module realizes real-time monitoring whether the PLC is normally connected, and if the PLC is failed to be connected, a message is sent to the alarm module so as to trigger alarm processing and related log records;
step S36: the program automatically tries to reconnect the PLC communication when disconnection occurs by setting conditions, and simultaneously records the connection times and the disconnection reason according to the conditions.
In one aspect of this embodiment, before monitoring the communication signals of the devices connected to the PLC, the method further includes:
step S40: establishing a mapping relation between the PLC and each equipment database, which specifically comprises the following steps:
step S41: establishing a mapping relation between an absolute address in the PLC and an equipment label by reading an equipment configuration document;
step S42: indexing the absolute address of the PLC database through the equipment tag, and establishing a mapping relation with each storage area of the PLC database;
step S43: after reading the stored data of the PLC, carrying out data type conversion according to requirements;
step S44: and establishing a mapping relation between the converted data and the label through the configuration document.
In one case of this embodiment, the establishing a PLC polling mechanism specifically includes:
step S50: establishing a mapping relation between the PLC and the workstation through an advanced configuration document;
step S51: controlling and polling a database area corresponding to each PLC through the monitoring point number; wherein the polling period can be set through a UI (user interface).
In one case of this embodiment, the data extracting and writing operation of the data acquisition module B specifically includes:
step S60: scanning data in a PLC database in the polling process, and sequentially storing the data in corresponding caches according to monitoring point numbers; wherein the cache access mode adopts a stack mode;
step S61: comparing the latest data scanned by current polling with the data in the last cache bit by bit;
step S62: in the bit-by-bit comparison, if the bit state is changed from 0 to 1, a new alarm is generated; if the bit state is changed from 1 to 0, ending the current alarm;
step S63: when a new alarm is generated, adding an alarm record to the database through the database statement; and when the alarm is finished, updating the finishing time originally recorded in the database to form a complete alarm time period.
Fig. 7 shows a detailed flowchart of the data acquisition module C in the PLC-based industrial device intelligent monitoring video acquisition method according to the embodiment of the present invention, where the core function of the data acquisition module C is to realize the timed query of the value of the identification variable and execute corresponding operations according to different values, and the main logic of the data acquisition module C is to realize the data cleaning function by regularly querying the value of each variable. The identification structure for supporting judgment mainly comprises the following identification variables:
the task judgment variable is used for judging whether new video data to be stored exist or not;
the task completion variable is used for judging whether the last local storage task is completed;
the storage completion variable is used for identifying whether the piece of data is a stored video recording or not;
the effective data time variable, the effective data monitoring point variable, the cache time variable and the cache monitoring point variable are used for judging whether repeated data to be stored exist.
The method comprises the following steps of regularly extracting data in a database through a data acquisition module C, and inquiring corresponding video recording files stored by a monitoring system according to the data in the database and the mark structure state generated in the data storage process, wherein the steps of:
inquiring the value of the task judgment variable, and judging whether data needing local video storage exists in a database of the data acquisition module B;
if the task judgment variable is equal to 0, the data with the storage completion variable being 0 does not exist in the current database, namely, the data to be effectively stored does not exist, the program will wait for the next query regularly until the task judgment variable is not equal to 0, and the data to be stored appears in the system;
for the task judgment variable, if the data of the row with the storage completion variable being 0 exists in the database table, the task judgment variable is not equal to 0, otherwise, the task judgment variable is equal to 0;
for the storage completion variable, all the 'storage completion variables' of the initial data inserted by the data acquisition module B are 0, the program firstly acquires the time point and the monitoring point data of the data to be stored in the data acquisition module B, assigns the time point and the monitoring point data to the 'effective data time variable' and the 'effective data monitoring point variable', assigns the time point and the 'cache monitoring point variable' simultaneously, judges whether the 'effective data time variable' and the 'effective data monitoring point variable' of the data are the same as the 'cache time variable' and the 'cache monitoring point variable' of the previous data when the program reads the next data, judges that the invalid data do not execute video storage action if the data are the same, and updates the 'storage completion variable' to 1; otherwise, the local video storage action is executed for the effective data, and the storage completion variable is updated to be 1;
the program executing the video storage action judges whether the last storage task is finished or not according to the value of the task completion variable, if the task completion variable is 0, the last storage action is not finished, the program waits for next query until the video storage action is finished, the program changes the task completion variable into 1, and the last video storage action is finished and the next video storage action can be carried out.
The equipment with PLC adopted by the method includes but is not limited to the equipment which is designed autonomously in the invention, and the general structure of the equipment is shown in figure 4, and the monitoring system adopted by the method includes but is not limited to the third party purchasing monitoring equipment used in the invention, and the general structure of the equipment is shown in figure 8.
In addition, the video capture method for the NVR device (shown in fig. 3) in the present invention may be replaced by a camera (shown in fig. 8) with a storage function in the image acquisition layer.
It should be understood that, although the steps in the flowcharts of the embodiments of the present invention are shown in sequence as indicated by the arrows, the steps are not necessarily executed in sequence as indicated by the arrows. The steps are not performed in the exact order shown and described, and may be performed in other orders, unless explicitly stated otherwise. Moreover, at least a portion of the steps in various embodiments may include multiple sub-steps or multiple stages that are not necessarily performed at the same time, but may be performed at different times, and the order of performance of the sub-steps or stages is not necessarily sequential, but may be performed in turn or alternately with other steps or at least a portion of the sub-steps or stages of other steps.
The technical features of the embodiments described above may be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the embodiments described above are not described, but should be considered as being within the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only represent some preferred embodiments of the present invention, and the description thereof is more specific and detailed, but not to be construed as limiting the scope of the present invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (8)
1. A PLC-based industrial equipment intelligent monitoring video acquisition method is characterized by comprising the following steps:
monitoring communication signals of each device connected with the PLC;
the method comprises the steps that state data of each device are obtained regularly through a data acquisition module A and stored in a PLC database;
acquiring event occurrence time and equipment information corresponding to the communication signals through the data acquisition module B, and comparing data acquired at different times bit by bit so as to filter out useless data and store the useful data in a database;
the data in the database is extracted in a timing mode through the data acquisition module C, and corresponding video recording files stored by the monitoring system are inquired according to the data in the database and the mark structure state generated in the data storage process;
and finally, video recording interception and local storage operation are carried out.
2. The method for collecting the intelligent monitoring video of the industrial equipment based on the PLC according to claim 1, wherein the step of obtaining the state data of each equipment in a timing manner and storing the state data into the PLC database through the data collecting module A specifically comprises the following steps:
establishing communication between the PLC and each external device through a standard protocol;
controlling the PLC to access a data storage area of the external equipment;
and defining data stored in the storage area of the external equipment according to the address of the storage area of the external equipment, and regularly storing the required data in a PLC database, thereby supporting data acquisition of the data acquisition module B.
3. The PLC-based industrial equipment intelligent monitoring video acquisition method as claimed in claim 1, wherein the data acquisition module B directly reads a PLC database, and simultaneously establishes a PLC polling mechanism, writes polled data into a memory of the data acquisition module B, compares the read data with the data in the memory during the next polling, and completes the data extraction and writing operations after the comparison.
4. The PLC-based industrial device intelligent surveillance video capture method of claim 1, wherein prior to monitoring communication signals of devices connected to the PLC, the method further comprises:
initializing the communication between each device and the PLC;
the initialization method specifically comprises the following steps:
loading the IP address and the port number of the PLC through the configuration document;
configuring TCP communication parameters through a circulation mode, and connecting corresponding PLCs one by one;
judging whether the connection between the PLC and the TCP is successful or not through a handshake signal fed back by the PLC;
multithreading in the module realizes real-time monitoring whether the PLC is normally connected, and if the PLC is failed to be connected, a message is sent to the alarm module so as to trigger alarm processing and related log records;
the program automatically tries to reconnect the PLC communication when disconnection occurs by setting conditions, and simultaneously records the connection times and the disconnection reason according to the conditions.
5. The PLC-based industrial device intelligent surveillance video capture method of claim 1, wherein prior to monitoring communication signals of devices connected to the PLC, the method further comprises:
establishing a mapping relation between the PLC and each equipment database;
the method for establishing the mapping relation specifically comprises the following steps:
establishing a mapping relation between an absolute address in the PLC and an equipment label by reading an equipment configuration document;
indexing the absolute address of the PLC database through the equipment tag, and establishing a mapping relation with each storage area of the PLC database;
after reading the stored data of the PLC, carrying out data type conversion according to requirements;
and establishing a mapping relation between the converted data and the label through the configuration document.
6. The PLC-based industrial equipment intelligent monitoring video acquisition method as claimed in claim 3, wherein the establishing of the PLC polling mechanism specifically comprises:
establishing a mapping relation between the PLC and the workstation through an advanced configuration document;
controlling and polling a database area corresponding to each PLC through the monitoring point number; wherein the polling period may be set via the UI.
7. The PLC-based industrial equipment intelligent monitoring video collecting method as claimed in claim 3, wherein the data extracting and writing operation of the data collecting module B specifically comprises:
scanning data in a PLC database in the polling process, and sequentially storing the data in corresponding caches according to monitoring point numbers; wherein the cache access mode adopts a stack mode;
comparing the latest data scanned by current polling with the data in the last cache bit by bit;
in the bit-by-bit comparison, if the bit state is changed from 0 to 1, a new alarm is generated; if the bit state is changed from 1 to 0, ending the current alarm;
when a new alarm is generated, adding an alarm record to the database through the database statement; and when the alarm is finished, updating the finishing time of the original record in the database to form a complete alarm time period.
8. The PLC-based industrial device intelligent monitoring video acquisition method according to any one of claims 1 to 7, wherein the extracting data in the database at regular time by the data acquisition module C, and querying the corresponding video recording file stored in the monitoring system according to the data in the database and the flag structure state generated in the data storage process specifically includes:
inquiring the value of the task judgment variable, and judging whether data needing local video storage exists in a database of the data acquisition module B;
if the task judgment variable is equal to 0, the data with the storage completion variable being 0 does not exist in the current database, namely, the data to be effectively stored does not exist, the program will wait for the next query regularly until the task judgment variable is not equal to 0, and the data to be stored appears in the system;
for the task judgment variable, if the data of the row with the storage completion variable being 0 exists in the database table, the task judgment variable is not equal to 0, otherwise, the task judgment variable is equal to 0;
for the storage completion variable, all the 'storage completion variables' of the initial data inserted by the data acquisition module B are 0, the program firstly acquires the time point and the monitoring point data of the data to be stored in the data acquisition module B, assigns the time point and the monitoring point data to the 'effective data time variable' and the 'effective data monitoring point variable', assigns the time point and the 'cache monitoring point variable' simultaneously, judges whether the 'effective data time variable' and the 'effective data monitoring point variable' of the data are the same as the 'cache time variable' and the 'cache monitoring point variable' of the previous data when the program reads the next data, judges that the invalid data do not execute video storage action if the data are the same, and updates the 'storage completion variable' to 1; otherwise, the local video storage action is executed for the effective data, and the storage completion variable is updated to be 1;
the program executing the video storage action judges whether the last storage task is finished or not according to the value of a task completion variable, if the task completion variable is 0, the last storage action is not finished, the program waits for next query until the video storage action is finished, the program changes the task completion variable into 1, and the last video storage action is finished and the next video storage action can be carried out;
the task judgment variable is used for judging whether new video data to be stored exist or not; the task completion variable is used for judging whether the last local storage task is completed; the storage completion variable is used for identifying whether the piece of data is a stored video; the effective data time variable, the effective data monitoring point variable, the cache time variable and the cache monitoring point variable are used for judging whether repeated data to be stored exist.
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