CN116151778B

CN116151778B - A Transformer Manufacturing Process Management System Based on Internet of Things

Info

Publication number: CN116151778B
Application number: CN202310433299.9A
Authority: CN
Inventors: 王龙燕; 陈文虹; 关念; 毛传松; 王刚; 王芳
Original assignee: Huainan Changlida Electric Co ltd
Current assignee: Huainan Changlida Electric Co ltd
Priority date: 2023-04-21
Filing date: 2023-04-21
Publication date: 2023-07-14
Anticipated expiration: 2043-04-21
Also published as: CN116151778A

Abstract

The invention provides a transformer manufacturing process management system based on the Internet of Things, which relates to the technical field of production management. The management system includes a production area division module, an Internet of Things monitoring module, a personnel management module, and a production management module; the production area division The module is used to divide the production area into several supervisory levels, and set corresponding supervisory force values for different supervisory levels, wherein, the higher the supervisory level, the greater the supervisory force value; the IoT monitoring module includes production equipment monitoring units and personnel Monitoring unit; by dividing the production areas, the present invention can manage the personnel and equipment in different production areas in a targeted manner, improve the comprehensiveness of the management of the production process, and ensure the safety of the production process, so as to solve the problem of existing production management The method is backward, and there are regulatory loopholes in the production management process, which is prone to production safety problems.

Description

Transformer production manufacturing process management system based on Internet of things

Technical Field

The invention relates to the technical field of production management, in particular to a transformer production and manufacturing process management system based on the Internet of things.

Background

The product production process refers to the whole process from raw material input to finished product output, and generally comprises a technological process, a checking process, a transportation process, a waiting and stopping process and a natural process. The process is the most basic part of the production process. Production management is a comprehensive management activity that plans, organizes, coordinates, and controls production activities. The content includes production plans, production organizations, and production controls. By reasonably organizing the production process, the production resources are effectively utilized, and the production activities are economically and reasonably carried out so as to achieve the expected production targets.

In the production and manufacturing process, the management of personnel in the existing production management technology is usually realized by a card punching mode, but the management mode is usually only used for attendance management of personnel, the personnel flow in a production area cannot be well monitored, in some key production areas, technicians not belonging to the production area enter at will, the problem that equipment operation causes damage to the personnel can occur, for example, in a processing workshop of mechanical parts, people with unclear safety rules of the processing workshop enter, the personnel and the equipment are damaged due to the fact that the equipment is easily touched by mistake, and meanwhile, the existing production management technology lacks of targeted management of the equipment, and the problem that equipment or personnel are damaged due to insufficient management in the production process can occur.

Disclosure of Invention

Aiming at the defects existing in the prior art, the invention can carry out targeted management on personnel and equipment in different production areas by dividing the production areas, improves the management comprehensiveness of the production process, ensures the safety of the production process, and solves the problems that the existing production management mode is behind, the production management process has a supervision loophole and the production safety is easy to occur.

In order to achieve the above purpose, the invention provides a transformer production manufacturing process management system based on the internet of things, which comprises a production area dividing module, an internet of things monitoring module, a personnel management module and a production management module;

the production area dividing module is used for dividing the production area into a plurality of supervision levels, and setting corresponding supervision values for different supervision levels, wherein the higher the supervision level is, the larger the supervision value is;

the monitoring module of the internet of things comprises a production equipment monitoring unit and a personnel monitoring unit, wherein the production equipment monitoring unit is used for monitoring the running state of production equipment, and the personnel monitoring unit is used for monitoring the area of personnel;

the personnel management module comprises a personnel division unit and a personnel risk management unit, wherein the personnel division unit is used for dividing personnel according to a production area, and the personnel risk management unit is used for carrying out personnel management risk monitoring according to the division of the personnel and the area to which the personnel belongs;

the production management module comprises an equipment risk management unit, wherein the equipment risk management unit is used for carrying out production equipment management risk monitoring according to the production area of equipment and the running state of production equipment.

Further, the production area division module is configured with a production area division policy, the production area division policy comprising: dividing a production area into a core production area, a key production area and a basic production area;

the method comprises the steps of setting a first supervision intensity value for a core production area, setting a second supervision intensity value for a key production area and setting a third supervision intensity value for a basic production area, wherein the first supervision intensity value is larger than the second supervision intensity value, and the second supervision intensity value is larger than the third supervision intensity value.

The production area division strategy further comprises: acquiring a production flow of a production manufacturing process, sequencing the production flow according to a front-to-back sequence, and corresponding the sequencing with a production area;

setting a production area positioned in a first proportion in the sequence as a core production area, setting a production area positioned between a second proportion and the first proportion in the sequence as a key production area, and setting a production area positioned behind the second proportion in the sequence as a basic production area;

the first supervision value is set to 3, the second supervision value is set to 2, and the third supervision value is set to 1.

Further, the production equipment monitoring unit comprises an infrared detector, the personnel monitoring unit comprises an internet of things connector, an access detection camera, an access radio frequency detector and a wireless connection detector, and a wireless connector and a radio frequency sensor are arranged in the internet of things connector;

the production equipment monitoring unit is configured with a production equipment monitoring strategy comprising: acquiring a supervision intensity value of a production area where production equipment is located, taking the supervision intensity value as a monitoring frequency of the production equipment in unit time, and controlling an infrared detector to acquire an infrared image of the production equipment according to the monitoring frequency;

the personnel monitoring unit is configured with personnel monitoring strategies, the personnel monitoring strategies comprising: carrying out wearing management on the connectors of the Internet of things for each person;

when a person enters a production area, verifying and detecting the person through a radio frequency sensor and an entrance detection camera;

setting the verification level of the entering detection camera to be higher than that of the radio frequency sensor, and counting the entering personnel when the face verification of the entering detection camera to the personnel passes; counting pending personnel for the entering personnel when the radio frequency sensor of the entering radio frequency detector passes the verification of the personnel and the face of the entering camera fails the verification of the personnel; when the radio frequency sensor of the entering radio frequency detector fails to verify the personnel and the entering camera fails to verify the personnel face of the personnel, counting the entering personnel at risk;

setting working time, and in the working time, when the wireless connection detector detects that the disconnection time of the wireless connector of personnel in the current production area exceeds a first risk duration, performing personnel supervision risk counting once; and when the wireless connection detector detects that the wireless connector matching connection time of the personnel not in the current production area exceeds the second risk duration, carrying out personnel approaching risk counting once.

Further, the personnel management module is configured with a attendance personnel management policy comprising: dividing the personnel according to the production areas of the personnel, and setting the count of the personnel which do not belong to the corresponding production area in the count of the matched personnel as the number of the personnel in other matched areas according to the division of the personnel;

setting the count of the personnel belonging to the corresponding production area in the matched personnel count as the number of the personnel in the complete matching area;

taking the supervision value corresponding to the current production area as the monitoring frequency in unit time of personnel risk;

in the working time, the number of the completely matched area personnel in the current production area is obtained, the number of basic matched personnel in the production area is set, the number of the completely matched area personnel in the current production area is obtained, and the number of the real-time matched personnel in the production area is set; comparing the number of real-time matching personnel in the production area with the number of basic matching personnel in the production area to obtain the ratio of attendance personnel in the production area;

setting a first attendance threshold for the core production area, a second attendance threshold for the key production area and a third attendance threshold for the basic production area; the first attendance threshold is greater than the second attendance threshold, which is greater than the third attendance threshold;

outputting a risk signal of insufficient supervision of the personnel in the core production area when the ratio of the personnel in the production area in the core production area is smaller than a first threshold value of the ratio of the personnel in the production area; outputting a risk signal of insufficient supervision of the personnel in the key production area when the ratio of the personnel in the production area in the key production area is smaller than a second threshold value of the ratio of the personnel in the production area; and outputting a risk signal of insufficient supervision of the basic production area personnel when the production area attendance ratio of the basic production area is smaller than the third attendance ratio threshold.

Further, the personnel management module is configured with a risk entry personnel management policy, the risk entry personnel management policy comprising: respectively acquiring the number of undetermined personnel counts and risk personnel counts of a core production area, a key production area and a basic production area;

calculating to obtain a risk value of the core risk entering personnel through a calculation formula of the core risk entering personnel; the core risk entering personnel calculation formula is configured as follows:

the method comprises the steps of carrying out a first treatment on the surface of the Wherein Fhj is a risk value of a core risk entering person, sdd is a count of undetermined persons in a core production area, sfx is a count of risk persons, and a1 isA1 and a2 are both greater than zero, a1 is less than a2, and a1+a2=1; calculating to obtain a key risk entering personnel risk value through a key risk entering personnel calculation formula; the key risk entering personnel calculation formula is configured as follows:

The method comprises the steps of carrying out a first treatment on the surface of the Wherein Fzj is a key risk entry personnel risk value; calculating to obtain a basic risk entering personnel risk value through a basic risk entering personnel calculation formula; the basic risk entering personnel calculation formula is configured as follows:

The method comprises the steps of carrying out a first treatment on the surface of the Wherein Fjj is a base risk entry personnel risk value;

outputting a core production area entering risk signal when the risk value of the core risk entering personnel is greater than or equal to a first entering risk threshold value; outputting a key production area entering risk signal when the key risk entering personnel risk value is greater than or equal to a second entering risk threshold value; when the risk value of the basic risk entering personnel is larger than or equal to a third entering risk threshold value, outputting a basic production area entering risk signal; the first entrance risk threshold is smaller than the second entrance risk threshold, and the second entrance risk threshold is smaller than the third entrance risk threshold.

Further, the personnel management module is configured with a supervisor management policy, the supervisor management policy comprising: respectively acquiring the number of personnel supervision risk counts of a core production area, a key production area and a basic production area;

setting a first supervision risk threshold value for the core production area, a second supervision risk threshold value for the key production area and a third supervision risk threshold value for the basic production area respectively; the first supervision risk threshold is smaller than the second supervision risk threshold, and the second supervision risk threshold is smaller than the third supervision risk threshold;

outputting a supervision failure signal of the core production area when the number of personnel supervision risk counts of the core production area is greater than a first supervision risk threshold; outputting a supervision failure signal of the key production area when the number of personnel supervision risk counts of the key production area is larger than a second supervision risk threshold; and outputting a basic production area supervision failure signal when the number of personnel supervision risk counts of the basic production area is greater than a third supervision risk threshold.

Further, the personnel management module is configured with a close personnel management policy, the close personnel management policy comprising: respectively acquiring the number of personnel approaching risk counts of a core production area, a key production area and a basic production area;

setting a first approach risk threshold value for the core production area, a second approach risk threshold value for the key production area and a third approach risk threshold value for the basic production area respectively; the first approach risk threshold is less than the second approach risk threshold, which is less than the third approach risk threshold;

outputting a core production area approaching risk signal when the number of personnel approaching risk counts of the core production area is greater than a first approaching risk threshold; outputting a critical production area approaching risk signal when the number of personnel approaching risk counts of the critical production area is larger than a second approaching risk threshold value; and outputting a base production area approaching risk signal when the number of personnel approaching risk counts of the base production area is greater than a third approaching risk threshold.

Further, the device risk management unit is configured with a device risk management policy, the device risk management policy comprising: acquiring an infrared image of production equipment in normal operation, and setting the infrared image as a basic reference image; acquiring a real-time infrared image of production equipment, and setting the real-time infrared image as a monitoring image;

setting the temperature value of the pixel points on the infrared image correspondingly, comparing the temperature value of the pixel points of the monitoring image with the temperature value of the pixel points of the basic reference image correspondingly, acquiring the number of pixels with the temperature value of the pixel points in the monitoring image larger than the temperature value of the pixel points in the basic reference image, setting the number of pixels as an overtemperature number, solving the proportion of the overtemperature number to the total number of the pixel points of the monitoring image, and setting the proportion as an overtemperature proportion;

obtaining the sum of the temperature values exceeding the overtemperature quantity, setting the sum as an overtemperature total value, and dividing the overtemperature total value by the overtemperature proportion to obtain an overtemperature reference value;

setting a first overtemperature threshold, a second overtemperature threshold and a third overtemperature threshold for the core production area, the key production area and the basic production area respectively; the first overtemperature threshold is smaller than the second overtemperature threshold, and the second overtemperature threshold is smaller than the third overtemperature threshold;

outputting a risk signal of equipment in the core production area when the overtemperature reference value of the core production area is larger than a first overtemperature threshold value; outputting a risk signal of equipment in the key production area when the overtemperature reference value of the key production area is larger than a second overtemperature threshold value; and outputting a risk signal of equipment in the basic production area when the over-temperature reference value of the basic production area is larger than a third over-temperature threshold value.

The invention has the beneficial effects that: according to the invention, the production area can be divided into a plurality of supervision levels through the production area dividing module, corresponding supervision values are set for different supervision levels, the higher the supervision level is, the larger the supervision value is, and the different production areas can be subjected to targeted management through the division of the production areas, so that the management accuracy is improved;

according to the invention, the operation state of the production equipment and the area of personnel can be monitored through the monitoring module of the Internet of things; the personnel management module can divide personnel according to the production area, and monitor personnel management risks according to the division of the personnel and the area to which the personnel belong; the design can increase the delicacy of personnel management and ensure the safety of personnel management in a production area; the production equipment management risk monitoring can be carried out according to the production area of the equipment and the running state of the production equipment through the production management module, the pertinence of the production equipment management in the production area can be improved, and the comprehensiveness of the running supervision of the production equipment is improved.

Additional aspects of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.

Drawings

Other features, objects and advantages of the present invention will become more apparent upon reading of the detailed description of non-limiting embodiments, given with reference to the accompanying drawings in which:

fig. 1 is a schematic block diagram of a management system of the present invention.

Fig. 2 is a schematic block diagram of an internet of things monitoring module according to the present invention.

Detailed Description

It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention.

Embodiments of the invention and features of the embodiments may be combined with each other without conflict.

Referring to fig. 1, the invention provides a transformer production and manufacturing process management system based on the internet of things, which can carry out targeted management on personnel and equipment in different production areas by dividing the production areas, improves the management comprehensiveness of the production process, and ensures the safety of the production process, so as to solve the problems that the existing production management mode is behind, the production management process has a supervision loophole, and the production safety is easy to occur.

Specifically, the management system comprises a production area dividing module, an internet of things monitoring module, a personnel management module and a production management module.

The production area dividing module is used for dividing the production area into a plurality of supervision levels, and setting corresponding supervision values for different supervision levels, wherein the higher the supervision level is, the larger the supervision value is; the production area division module is configured with a production area division strategy, and the production area division strategy comprises the following steps:

step S11, dividing a production area into a core production area, a key production area and a basic production area; acquiring a production flow of a production manufacturing process, sequencing the production flow according to a front-to-back sequence, and corresponding the sequencing with a production area;

step S12, setting a production area positioned in a first proportion in the sequence as a core production area, setting a production area positioned in the sequence between a second proportion and the first proportion as an important production area, and setting a production area positioned behind the second proportion in the sequence as a basic production area; in the implementation, for example, in an electronic device production area, a core production area such as a welding area, a key production area such as a packaging area, and a basic production area such as a packaging area; the first ratio was set to 30% and the second ratio was set to 60%;

step S13, a first supervision value is set for the core production area, a second supervision value is set for the key production area, and a third supervision value is set for the basic production area, wherein the first supervision value is larger than the second supervision value, the second supervision value is larger than the third supervision value, and in specific implementation, the first supervision value is set to 3, the second supervision value is set to 2, and the third supervision value is set to 1.

Referring to fig. 2, the monitoring module of the internet of things includes a production equipment monitoring unit for monitoring an operation state of the production equipment and a personnel monitoring unit for monitoring a region to which a person belongs; specifically, the production equipment monitoring unit comprises an infrared detector, the personnel monitoring unit comprises an internet of things connector, an entering detection camera, an entering radio frequency detector and a wireless connection detector, the wireless connection detector is used for detecting whether the wireless connector is connected with wireless connection transfer equipment in a production area or not, so that whether personnel are in the production area or not is judged, the entering radio frequency detector is existing radio frequency card swiping equipment, a wireless connector and a radio frequency sensor are arranged in the internet of things connector, the internet of things connector can be mobile phone equipment of the personnel, the wireless connector in the mobile phone equipment can be a wireless network connection unit or a Bluetooth unit, and the radio frequency sensor can be an NFC unit;

the production facility monitoring unit is configured with a production facility monitoring strategy comprising the steps of:

step S211, acquiring a supervision value of a production area where production equipment is located, taking the supervision value as a monitoring frequency of the production equipment in unit time, and controlling an infrared detector to acquire an infrared image of the production equipment according to the monitoring frequency;

the personnel monitoring unit is configured with personnel monitoring strategies, and the personnel monitoring strategies comprise the following steps:

step S221, carrying out wearing management of the connectors of the Internet of things on each person;

step S222, when a person enters a production area, verifying and detecting the person through a radio frequency sensor and an entrance detection camera;

step S223, setting the verification level of the entering detection camera to be higher than that of the radio frequency sensor, and counting the entering personnel when the face verification of the entering detection camera to the personnel passes; counting pending personnel for the entering personnel when the radio frequency sensor of the entering radio frequency detector passes the verification of the personnel and the face of the entering camera fails the verification of the personnel; when the radio frequency sensor of the entering radio frequency detector fails to verify the personnel and the entering camera fails to verify the personnel face of the personnel, counting the entering personnel at risk;

step S224, each production area has working time, personnel are monitored in the working time, the working time is set, and in the working time, when the wireless connection detector detects that the disconnection time of the wireless connector of the personnel in the current production area exceeds a first risk duration, the first risk duration can be specifically set to be 10-20min, and personnel monitoring risk counting is carried out once; when the wireless connection detector detects that the wireless connector matching connection time of the personnel not belonging to the current production area exceeds the second risk duration, the second risk duration can be set to 3-10min, and the personnel approaching risk count is carried out once.

The personnel management module comprises a personnel division unit and a personnel risk management unit, wherein the personnel division unit divides personnel according to the production area, and the personnel risk management unit is used for carrying out personnel management risk monitoring according to the division of the personnel and the area to which the personnel belongs; the personnel management module is configured with a attendance management policy comprising the steps of:

step S311, dividing the personnel according to the production areas of the personnel, and setting the count of the personnel which do not belong to the corresponding production area in the count of the matched personnel as the number of the personnel in other matched areas according to the division of the personnel; the working content of the personnel in each production area is different, and the corresponding production safety knowledge fields and ranges are different, so that the situation that personnel are accidentally injured due to misoperation of equipment easily occurs when the personnel in different production areas walk mutually;

step S312, the count of the personnel belonging to the corresponding production area in the matched personnel count is set as the number of the personnel in the complete matched area;

step S313, taking the supervision value corresponding to the current production area as the monitoring frequency in unit time of personnel risk; the unit time is set to be 1h, and as the first supervision value is set to be 3, the second supervision value is set to be 2, and the third supervision value is set to be 1, the monitoring frequency of the core production area, the key production area and the basic production area is respectively set to be 3, 2 and 1 time within 1 h;

step S314, acquiring the number of the completely matched area personnel in the current production area in the working time, setting the number of basic matched personnel in the production area, acquiring the number of the completely matched area personnel in the current production area in real time, and setting the number of the matched personnel in the production area in real time; comparing the number of real-time matching personnel in the production area with the number of basic matching personnel in the production area to obtain the ratio of attendance personnel in the production area;

step S315, a first attendance threshold is set for a core production area, a second attendance threshold is set for a key production area, and a third attendance threshold is set for a basic production area; the first attendance threshold is greater than the second attendance threshold, which is greater than the third attendance threshold; in particular implementations, the first, second, and third attendance thresholds are set to 80%, 60%, and 50%, respectively;

step S315, when the ratio of the production area attendance of the core production area is smaller than a first attendance ratio threshold, outputting a risk signal of insufficient supervision of the personnel of the core production area; outputting a risk signal of insufficient supervision of the personnel in the key production area when the ratio of the personnel in the production area in the key production area is smaller than a second threshold value of the ratio of the personnel in the production area; and outputting a risk signal of insufficient supervision of the basic production area personnel when the production area attendance ratio of the basic production area is smaller than the third attendance ratio threshold.

The personnel management module is configured with a risk entry personnel management strategy, and the risk entry personnel management strategy comprises the following steps:

step S321, respectively acquiring the number of pending personnel counts and risk personnel counts of a core production area, a key production area and a basic production area;

step S322, calculating to obtain a risk value of the core risk entering personnel through a calculation formula of the core risk entering personnel; the core risk entering personnel calculation formula is configured as follows:

the method comprises the steps of carrying out a first treatment on the surface of the Fhj is a core risk entering personnel risk value, sdd is pending personnel count of a core production area and Sfx is the number of risk personnel counts, a1 is a first proportionality constant, a2 is a second proportionality constant, a1 and a2 are both greater than zero, a1 is less than a2, and a1+a2=1; in the implementation, the entrance risk of the same number of risk personnel is greater than that of the undetermined personnel, a1 is set to 0.3, and a2 is set to 0.7; calculating to obtain a key risk entering personnel risk value through a key risk entering personnel calculation formula; the key risk entering personnel calculation formula is configured as follows:

step S323, when the risk value of the core risk entering personnel is greater than or equal to the first entering risk threshold value, outputting a core production area entering risk signal; outputting a key production area entering risk signal when the key risk entering personnel risk value is greater than or equal to a second entering risk threshold value; when the risk value of the basic risk entering personnel is larger than or equal to a third entering risk threshold value, outputting a basic production area entering risk signal; the first entering risk threshold is smaller than the second entering risk threshold, the second entering risk threshold is smaller than the third entering risk threshold, and the first entering risk threshold, the second entering risk threshold and the third entering risk threshold are respectively set to be 5, 10 and 15 in specific implementation.

The personnel management module is configured with a supervisor management policy, and the supervisor management policy comprises the following steps:

step S331, respectively acquiring the number of personnel supervision risk counts of a core production area, a key production area and a basic production area;

step S332, a first supervision risk threshold is set for the core production area, a second supervision risk threshold is set for the key production area, and a third supervision risk threshold is set for the basic production area; the first supervision risk threshold is smaller than the second supervision risk threshold, and the second supervision risk threshold is smaller than the third supervision risk threshold; in specific implementation, the first supervision risk threshold, the second supervision risk threshold and the third supervision risk threshold are respectively set to 2, 5 and 10;

step S333, outputting a supervision failure signal of the core production area when the number of personnel supervision risk counts of the core production area is greater than a first supervision risk threshold; outputting a supervision failure signal of the key production area when the number of personnel supervision risk counts of the key production area is larger than a second supervision risk threshold; and outputting a basic production area supervision failure signal when the number of personnel supervision risk counts of the basic production area is greater than a third supervision risk threshold.

The personnel management module is configured with a personnel approaching management strategy, and the personnel approaching management strategy comprises the following steps:

step S341, respectively acquiring the number of personnel approaching risk counts of a core production area, a key production area and a basic production area;

step S342, a first approach risk threshold is set for the core production area, a second approach risk threshold is set for the key production area, and a third approach risk threshold is set for the basic production area; the first approach risk threshold is less than the second approach risk threshold, which is less than the third approach risk threshold; in specific implementation, the first approach risk threshold, the second approach risk threshold and the third approach risk threshold are respectively set to 2, 5 and 10;

step S343, when the number of the personnel approaching risk counts of the core production area is greater than the first approaching risk threshold, outputting a core production area approaching risk signal; outputting a critical production area approaching risk signal when the number of personnel approaching risk counts of the critical production area is larger than a second approaching risk threshold value; and outputting a base production area approaching risk signal when the number of personnel approaching risk counts of the base production area is greater than a third approaching risk threshold.

The production management module comprises an equipment risk management unit, and the equipment risk management unit is used for carrying out production equipment management risk monitoring according to the production area of equipment and the running state of production equipment.

The device risk management unit is configured with a device risk management policy comprising the steps of:

step S41, acquiring an infrared image of production equipment in normal operation, and setting the infrared image as a basic reference image; acquiring a real-time infrared image of production equipment, and setting the real-time infrared image as a monitoring image;

step S42, performing corresponding setting of temperature values on pixels on the infrared image, performing corresponding comparison of temperature values of the pixels on the monitoring image and the basic reference image, obtaining the number of pixels with the temperature values of the pixels in the monitoring image being larger than the temperature values of the pixels in the basic reference image, setting the number of pixels as an overtemperature number, solving the proportion of the overtemperature number to the total number of the pixels in the monitoring image, and setting the proportion as an overtemperature proportion;

step S43, obtaining the sum of the temperature values exceeding the overtemperature quantity, setting the sum as the overtemperature total value, and dividing the overtemperature total value by the overtemperature proportion to obtain an overtemperature reference value;

step S44, a first overtemperature threshold is set for the core production area, a second overtemperature threshold is set for the key production area, and a third overtemperature threshold is set for the basic production area; the first overtemperature threshold is smaller than the second overtemperature threshold, and the second overtemperature threshold is smaller than the third overtemperature threshold; in specific implementation, the first overtemperature threshold, the second overtemperature threshold and the third overtemperature threshold are respectively set to 100, 200 and 300;

step S45, outputting a risk signal of equipment in the core production area when the overtemperature reference value of the core production area is larger than a first overtemperature threshold value; outputting a risk signal of equipment in the key production area when the overtemperature reference value of the key production area is larger than a second overtemperature threshold value; and outputting a risk signal of equipment in the basic production area when the over-temperature reference value of the basic production area is larger than a third over-temperature threshold value.

Working principle: firstly, a plurality of supervision grades of the production area can be classified by a production area classifying module, corresponding supervision values are set for different supervision grades, the higher the supervision grade is, the larger the supervision values are, the different production areas can be subjected to targeted management by classifying the production areas, and then the running state of production equipment and the area of personnel can be monitored by an Internet of things monitoring module; the personnel management module can divide personnel according to the production area, and monitor personnel management risks according to the division of the personnel and the area to which the personnel belong; the production equipment management risk monitoring can be carried out according to the production area of the equipment and the running state of the production equipment through the production management module, and the pertinence and the comprehensiveness of personnel and production equipment management in the production area can be improved.

It will be appreciated by those skilled in the art that embodiments of the present invention may be provided as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media having computer-usable program code embodied therein. The storage medium may be implemented by any type or combination of volatile or nonvolatile Memory devices, such as static random access Memory (Static Random Access Memory, SRAM), electrically erasable Programmable Read-Only Memory (Electrically Erasable Programmable Read-Only Memory, EEPROM), erasable Programmable Read-Only Memory (Erasable Programmable Read Only Memory, EPROM), programmable Read-Only Memory (PROM), read-Only Memory (ROM), magnetic Memory, flash Memory, magnetic disk, or optical disk. These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.

The above examples are only specific embodiments of the present invention, and are not intended to limit the scope of the present invention, but it should be understood by those skilled in the art that the present invention is not limited thereto, and that the present invention is described in detail with reference to the foregoing examples: any person skilled in the art may modify or easily conceive of the technical solution described in the foregoing embodiments, or perform equivalent substitution of some of the technical features, while remaining within the technical scope of the present disclosure; such modifications, changes or substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention, and are intended to be included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims

1. A transformer manufacturing process management system based on the Internet of Things (IoT), characterized in that the management system includes a production area division module, an IoT monitoring module, a personnel management module, and a production management module;

The production area division module is used to divide the production area into several regulatory levels and set corresponding regulatory intensity values for different regulatory levels. The higher the regulatory level, the greater the regulatory intensity value.

The IoT monitoring module includes a production equipment monitoring unit and a personnel monitoring unit. The production equipment monitoring unit is used to monitor the operating status of the production equipment, and the personnel monitoring unit is used to monitor the area to which the personnel belong.

The personnel management module includes a personnel division unit and a personnel risk management unit. The personnel division unit divides personnel according to production areas, and the personnel risk management unit is used to monitor personnel management risks based on personnel division and the area to which the personnel belong.

The production management module includes an equipment risk management unit, which is used to monitor production equipment management risks based on the production area of the equipment and the operating status of the production equipment.

The production area division module is configured with a production area division strategy, which includes dividing the production area into core production areas, key production areas, and basic production areas.

A first level of regulatory intensity is set for the core production area, a second level of regulatory intensity is set for the key production area, and a third level of regulatory intensity is set for the basic production area. The first level of regulatory intensity is greater than the second level of regulatory intensity, and the second level of regulatory intensity is greater than the third level of regulatory intensity.

The production area division strategy also includes: obtaining the production process flow of the manufacturing process, sorting the production process flow in sequence, and mapping the sorting to production areas;

The production areas that rank first in the sort are designated as core production areas, the production areas that rank between the second and first proportions are designated as key production areas, and the production areas that rank after the second proportion are designated as basic production areas.

The first regulatory intensity value is set to 3, the second regulatory intensity value is set to 2, and the third regulatory intensity value is set to 1.

The production equipment monitoring unit includes an infrared detector, and the personnel monitoring unit includes an IoT connector, an entry detection camera, an entry radio frequency detector, and a wireless connection detector. The IoT connector is equipped with a wireless connector and a radio frequency sensor.

The production equipment monitoring unit is configured with a production equipment monitoring strategy, which includes: obtaining the supervision intensity value of the production area where the production equipment is located, using the supervision intensity value as the monitoring frequency of the production equipment per unit time, and controlling the infrared detector to obtain the infrared image of the production equipment according to the monitoring frequency;

The personnel monitoring unit is configured with a personnel monitoring strategy, which includes: managing the wearing of IoT connectors for each person;

When personnel enter the production area, they are verified and detected by radio frequency sensors and entry detection cameras.

The verification level of the entry detection camera is set higher than that of the radio frequency sensor. When the entry detection camera passes the facial verification of a person, the person entering is counted as a matched person. When the entry radio frequency detector passes the radio frequency sensor verification of a person but the entry camera fails the facial verification of a person, the person entering is counted as a pending person. When the entry radio frequency detector fails the radio frequency sensor verification of a person and the entry camera fails the facial verification of a person, the person entering is counted as a risk person.

Set working hours. During working hours, when the wireless connection detector detects that the wireless connector disconnection time of personnel belonging to the current production area exceeds the first risk duration, a personnel supervision risk count is performed; when the wireless connection detector detects that the wireless connector matching connection time of personnel not belonging to the current production area exceeds the second risk duration, a personnel approach risk count is performed.

The personnel management module is configured with an attendance personnel management strategy, which includes: dividing personnel according to their production area, and setting the count of personnel in the matching personnel count that do not belong to the corresponding production area to the number of personnel in other matching areas based on the personnel division;

Set the count of personnel belonging to the corresponding production area in the matched personnel count to the number of personnel in the fully matched area;

The current regulatory intensity value corresponding to the production area is used as the monitoring frequency of personnel risk per unit time.

During working hours, obtain the number of fully matched personnel in the current production area when all personnel are present, and set it as the basic matched personnel number in the production area. Obtain the real-time number of fully matched personnel in the current production area and set it as the real-time matched personnel number in the production area. Compare the real-time matched personnel number in the production area with the basic matched personnel number in the production area to obtain the attendance ratio in the production area.

A first attendance ratio threshold is set for core production areas, a second attendance ratio threshold is set for key production areas, and a third attendance ratio threshold is set for basic production areas; the first attendance ratio threshold is greater than the second attendance ratio threshold, and the second attendance ratio threshold is greater than the third attendance ratio threshold.

When the attendance ratio of production area personnel in the core production area is less than the first attendance ratio threshold, a risk signal of insufficient supervision of personnel in the core production area is output; when the attendance ratio of production area personnel in the key production area is less than the second attendance ratio threshold, a risk signal of insufficient supervision of personnel in the key production area is output; when the attendance ratio of production area personnel in the basic production area is less than the third attendance ratio threshold, a risk signal of insufficient supervision of personnel in the basic production area is output.

The personnel management module is configured with a risk entry personnel management strategy, which includes: obtaining the number of pending personnel and risk personnel in the core production area, key production area and basic production area respectively;

The risk value of personnel entering the core risk area is calculated using the core risk entry personnel calculation formula; the core risk entry personnel calculation formula is configured as follows:

Where Fhj is the risk value of personnel entering the core risk area, Sdd is the count of pending personnel in the core production area, Sfx is the number of risk personnel, a1 is the first proportional constant, a2 is the second proportional constant, both a1 and a2 are greater than zero, a1 is less than a2, and a1+a2=1; the risk value of personnel entering the key risk area is calculated using the key risk entry personnel calculation formula; the key risk entry personnel calculation formula is configured as follows:

Wherein, Fzj is the risk value of key risk personnel entering the area; the risk value of basic risk personnel entering the area is calculated using the basic risk personnel entry calculation formula; the basic risk personnel entry calculation formula is configured as follows:

Among them, Fjj is the basic risk entry personnel risk value;

When the risk value of personnel entering a core risk area is greater than or equal to the first entry risk threshold, an entry risk signal for the core production area is output; when the risk value of personnel entering a key risk area is greater than or equal to the second entry risk threshold, an entry risk signal for the key production area is output; when the risk value of personnel entering a basic risk area is greater than or equal to the third entry risk threshold, an entry risk signal for the basic production area is output; wherein, the first entry risk threshold is less than the second entry risk threshold, and the second entry risk threshold is less than the third entry risk threshold.

The personnel management module is configured with a supervisory personnel management strategy, which includes: obtaining the number of personnel supervision risk counts in the core production area, key production area and basic production area respectively;

A first regulatory risk threshold is set for core production areas, a second regulatory risk threshold is set for key production areas, and a third regulatory risk threshold is set for basic production areas; the first regulatory risk threshold is lower than the second regulatory risk threshold, and the second regulatory risk threshold is lower than the third regulatory risk threshold.

When the number of personnel supervision risk counts in the core production area exceeds the first supervision risk threshold, a signal of inadequate supervision in the core production area is output; when the number of personnel supervision risk counts in the key production area exceeds the second supervision risk threshold, a signal of inadequate supervision in the key production area is output; when the number of personnel supervision risk counts in the basic production area exceeds the third supervision risk threshold, a signal of inadequate supervision in the basic production area is output.

The personnel management module is configured with a personnel proximity management strategy, which includes: obtaining the number of personnel proximity risk counts for the core production area, key production area, and basic production area, respectively.

A first proximity risk threshold is set for the core production area, a second proximity risk threshold is set for the key production area, and a third proximity risk threshold is set for the basic production area; the first proximity risk threshold is less than the second proximity risk threshold, and the second proximity risk threshold is less than the third proximity risk threshold.

When the number of personnel approaching the risk in the core production area exceeds the first risk threshold, a risk signal is output for the core production area; when the number of personnel approaching the risk in the key production area exceeds the second risk threshold, a risk signal is output for the key production area; when the number of personnel approaching the risk in the basic production area exceeds the third risk threshold, a risk signal is output for the basic production area.

2. The transformer manufacturing process management system based on the Internet of Things according to claim 1, characterized in that the equipment risk management unit is configured with an equipment risk management strategy, the equipment risk management strategy including: acquiring infrared images of the production equipment during normal operation and setting them as the basic reference images; acquiring real-time infrared images of the production equipment and setting them as monitoring images;

The pixels in the infrared image are set to correspond to temperature values. The temperature values of the pixels in the monitoring image are compared with those in the base reference image. The number of pixels in the monitoring image whose temperature values are greater than those in the base reference image is set as the over-temperature number. The proportion of the over-temperature number to the total number of pixels in the monitoring image is calculated and set as the over-temperature ratio.

Get the sum of the temperature values that exceed the number of over-temperature values, set it as the total over-temperature value, and divide the total over-temperature value by the over-temperature ratio to obtain the over-temperature reference value.

A first over-temperature threshold is set for the core production area, a second over-temperature threshold is set for the key production area, and a third over-temperature threshold is set for the basic production area; the first over-temperature threshold is less than the second over-temperature threshold, and the second over-temperature threshold is less than the third over-temperature threshold.

When the over-temperature reference value of the core production area exceeds the first over-temperature threshold, a risk signal for the equipment in the core production area is output; when the over-temperature reference value of the key production area exceeds the second over-temperature threshold, a risk signal for the equipment in the key production area is output; when the over-temperature reference value of the basic production area exceeds the third over-temperature threshold, a risk signal for the equipment in the basic production area is output.