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1 Program overview
With the advent of the Internet of Things era, the market competition in the manufacturing industry has changed from the competition of single advanced equipment, single process technology, etc. to the competition of comprehensive production information processing capabilities. It is no longer simply a change in competition styles and methods, but a competition pattern. Change, the internal information processing capability of an enterprise has become the primary indicator to measure the competitiveness of an enterprise
Guangzhou Leerpu Information Technology Co., Ltd., this system uses advanced Internet of Things information technology to realize the connection and integration of the material trolley installation identification card on the production site with the back-end system. The system can intelligently perceive the position information and walking route of each material trolley. , When the state of the material trolley is abnormal, the system can send the alarm message to the relevant personnel via email, mobile phone text message, APP information, etc. The system simplifies complicated process operations and a large amount of statistical time and time to fill in reports, realizes the flattening of organizational information exchange, realizes real-time information sharing, and improves the response speed and efficiency of the enterprise.
2 System principle
2.1 Working principle
The program mainly uses RFID technology to transmit information to the collection server through wireless communication technology through low-frequency locators, identification cards and base stations and other terminal equipment, and realizes various upper-level applications. The system terminals mainly include low-frequency locators, base stations, Identification card, acquisition system.
Low-frequency locator: Active transmitter. When the identification card enters the low-frequency signal range, it can receive 125KHZ low-frequency signals continuously sent by the locator. The signal includes its own number, which can be used to distinguish and identify different locators. It is 2~8m.
Identification card: It is installed for items or tools that need to be monitored. It has a unique number and can actively accept 125KHz low-frequency signals and upload relevant information through 2.4G. It can realize identity authentication, location tracking and monitoring functions.
Base station: It is mainly used as an information transmission equipment to achieve full coverage of signals in the hospital’s monitoring area, and can receive information sent by the card and upload the information to the collection server.
Acquisition system: Process the data uploaded by the base station to realize various upper-level applications.
2.2 Introduction to RFID technology
RFID (Radio Frequency Identification Technology) is a non-contact latest automatic identification technology that matured at the end of the 20th century and the beginning of the 21st century. It is currently being promoted and applied in various industries all over the world.
It uses radio frequency signals to automatically identify target objects and obtain relevant data.
RFID is a flexible application technology that is easy to control, simple and practical, and especially suitable for automatic control. Its unique advantages are beyond the reach of other identification technologies.
The identification work does not require manual intervention;
It can support both read-only working mode and read-write working mode without contact or precise aiming;
Can work freely in various harsh environments;
Can carry out a high degree of data integration;
Because this technology is difficult to be counterfeited or invaded, RFID has a very high security protection capability.
This system generally includes the following parts:
Identification card: It is composed of coupling components and chips. Each tag has a unique electronic code, which is attached to the object to identify the target object;
Base station: a device for reading (and sometimes writing) tag information, which can be designed as a handheld or fixed type;
Antenna: Transmit radio frequency signals between the tag and the reader.
Locator: send out low-frequency signal, identification card recognizes low-frequency signal to realize precise positioning
The identification card generally stores electronic data in an agreed format. In practical applications, the identification card is attached to the surface of the object to be identified. The base station can read and identify the electronic data stored in the identification card without contact, so as to achieve the purpose of automatically identifying the body. Usually the base station is connected to a computer, and the read identification card information is transmitted to the computer for further processing. (In addition to the above basic hardware configuration, corresponding application software should also be included).
3 System function
3.1 System overview
This system installs electronic tags on objects that need to be monitored, such as material trolleys, etc., to manage the location and information of the trolleys, and when there is an error in the parking position of the trolley, abnormal walking route, wrong delivery destination, or long stay time When waiting for an abnormal situation, the system will take the initiative to pop up an alarm prompt to remind relevant personnel to follow up. The location information is mainly sensed by the identification card to fix the locator on the channel (such as the door, corridor entrance) or the production line, and the data is transmitted back to the base station and then wirelessly or wiredly transmitted to the internal LAN network and then to the server, finally realizing real-time management information.
3.1.1 Software system structure
Software system structure diagram
3.1.2 System main interface
The main interface of the system includes a map interface, a menu bar, and a function bar. The map interface will be drawn according to the actual situation of the customer site.
System main interface diagram
3.1.3 Brief description of functions
Entry and exit records: real-time check at which doorway and time each trolley passed, and the status of the passing time (that is, entering/exiting), and real-time view of the passing trolleys at each doorway, and finally form a statistical report for relevant management personnel to view and analyze .
Positioning and tracking: Use active RFID radio frequency identification technology to realize the function of positioning, tracking and monitoring items, and display them dynamically in the system interface.
Track query: query and print historical tracks, historical data reports, etc.
Information query: When the trolley passes through a specific area, the system automatically displays the identity information of the trolley and the information of the materials being transported.
Alarm management: display route error alarm, destination error alarm, stay time overtime alarm, equipment failure alarm, etc.
3.2 Application function
3.2.1 Entry and exit records
On the real-time entry and exit page, the real-time entry and exit records of each trolley can be displayed, such as where the current location is, whether the status is entering or leaving, and the entry and exit statistical report can be generated by time period.
Real-time car entry and exit renderings
3.2.2 Real-time location tracking
By installing identification cards on the material trucks and jigs that need to be monitored, and using items with unique identification, the system can display the location and status of personnel in real time based on the radio frequency information of the identification card, and mark them on the map as needed. At the same time, the designated identification card can be tracked in real time, and the moving route of the tracked item will be dynamically displayed on the map.
The positioning effect diagram is as follows:
Positioning effect chart
3.2.3 Track record and playback
The system can record the movement trajectory of each material truck and fixture in real time, and provide query historical location record data. At the same time, it can play back the track data of any identification card, and play it back on the map according to the time period (with or without track, setting the playback speed, etc.).
Trolley trajectory diagram
3.2.4 Alarm management
The system can locate and alarm the car in real time, and send the alarm information to designated personnel via email and text message for confirmation.
General alarms have the following categories:
Route error alarm
The system can set the material distribution route of each workshop. When the material distribution error material truck does not follow the set route, the system can automatically recognize and prompt the alarm in time, and the relevant personnel can confirm it in time to prevent the wrong material from affecting production.
Stay overtime alarm
The system can set the stay time. When the trolley stays at a certain location for longer than the set time during the process of distributing materials, the system will actively send out an alarm to prevent the trolley from staying at a destination for an extended period of time without any reason and hindering others Use a trolley.
Equipment failure alarm
It is mainly to give an alarm for the failure of equipment such as identification cards and base stations, such as signal disappearance, signal interruption, and insufficient battery power of the equipment, etc., to remind relevant personnel to check.
Delivery destination error alarm
The system sets the delivery destination of the trolley. When the trolley sends materials and other items to another place by mistake, the system will give the relevant personnel an alarm, so that the relevant personnel can deal with it in time, effectively preventing unnecessary losses due to errors.
3.3 Extended functions
3.3.1 Video linkage management
The video linkage function is to bind the base station with the video surveillance equipment. When an alarm occurs, the system will promptly call the video surveillance equipment to the place where the incident occurred and record the video information of the alarm location, and vice versa, that is, when the surveillance equipment finds that there is When a suspicious situation occurs, the system will promptly call the intelligent management system to locate, analyze and record the personnel in the monitoring area.
The system can directly use the existing video equipment in the factory, without the need to purchase additional video equipment to realize the video linkage function, reducing construction costs.
3.3.2 LED smart display
LED display screens can be installed in each key channel and connected to the system. When the trolley passes through the channel, the display screen displays the information of the trolley, including the identity information of the trolley, and information such as the name and quantity of the material being transported.
4 Overall scheme design
4.1 The overall layout design of the system
The system arranges locators in the production workshops, floors, warehouses, passages and other places in the factory according to customer requirements to realize personnel positioning, deploy base stations to achieve signal coverage, and distribute corresponding electronic tags to the material trucks and fixtures that need to be monitored. , So as to realize intelligent monitoring and management.
Description of distribution situation:
Locator: Active transmitter. When the identification card enters the low-frequency signal range, it can receive the 125KHZ low-frequency signal continuously sent by the locator. It is divided into four antennas and two antennas. Each antenna signal includes its own number. It can be used to distinguish and identify different locator numbers, and can be combined with the existing building environment of the factory to locate the production workshop and production line. The signal range in the actual environment is 2-8m.
Outdoor base station: It is used to cover all the open environment signal reception of non-buildings in the factory.
Indoor base station: It is used to fully cover the reception of signals inside all buildings.
4.2 Overall system architecture
Schematic diagram of the overall system architecture
The overall structure of the system mainly includes four parts: front-end data acquisition system, data transmission system, data processing service system and Web upper application system.
The front-end data acquisition system is an RFID wireless transmission system, which is mainly composed of a radio frequency identification card, a low-frequency locator, an RFID base station, and a field bus/local area network. Its main function is to wirelessly collect target location data and other data sent by the identification card.
The data transmission system is mainly composed of a data collection computer, a data server and a dedicated upload line. The main function is to upload the collected data to the data center for storage and processing.
The data processing service system mainly includes GIS system, application server, system management workstation, etc. The system is located in the monitoring center, and its main function is to analyze and process data and provide various data services for the upper application system.
The upper-level web application system mainly uses the data collected by the collection system to display various business functions through the software platform, display intuitive effects to the factory management, and realize statistical management of various data reports.
5 Product configuration
5.1 Base station
Product Image
product description
The BWBS type base station is a long-distance active RFID reading and writing device, which has the characteristics of long recognition distance, high sensitivity, fast recognition speed, and strong anti-interference ability. It is directly fixed by screws and is firmly installed. It can be used indoors and outdoors. It is widely used in areas such as the location and tracking of personnel and assets in the area, and access control management.
The BWBS base station carries out two-way data communication with the monitoring center through Ethernet or WIFI, uploads all the information of the identification card to the monitoring center in real time, and provides the system with high-precision and real-time data.
Main Specifications
Outdoor base station:
Displacement speed: 180km/h
Concurrent identification number: more than 500
Missing reading rate: 10-4
Recognition angle: support omnidirectional and directional (horizontal 45°, vertical 45°)
Polarization method: vertical polarization
Gain: omnidirectional antenna 3dBi, directional antenna 14dBi
16 levels adjustable for receiving, 16 levels adjustable for transmitting
Working frequency: 2.4～2.483GHz
Power consumption standard: RF working power consumption is milliwatt level
Security: encryption algorithm and matching mechanism to prevent link detection and cracking
Shell material: ABS engineering plastic
Environmental adaptability: Water-proof and shock-proof design, meeting the requirements of industrial environment, protection level up to IP65.
Interface standard: RJ45, RS485, wireless WIFI
Power standard: DC12V～48V
Dimensions: 185×132×75(mm)
Weight: 1.7kg
Working temperature: -20℃～60℃
Storage temperature: -40℃～60℃
Installation method: side installation, supporting special installation back plate, hose clamp binding or screw fixing
Detailed description
Operating mode
The BWBS base station is a long-distance active RFID reading and writing device that receives BWTF series identification card information in real time. Two-way data communication is carried out with the monitoring center via Ethernet or WIFI, and all information of the identification card is uploaded to the monitoring center in real time, providing high-precision and real-time data for the system.
Frequency band selection
The 2.4G frequency band is selected, which belongs to the open ISM microwave frequency band in the world, and there is no need to apply and pay.
Recognition distance
The design adopts high-performance radio frequency solutions to realize long-distance radio frequency identification. The recognition distance is as follows:
Omnidirectional antenna 120 meters (with BWTF series identification card, no obstruction in the air),
Directional antenna 300 meters (with BWTF series identification card, no obstruction in the air);
When users have different requirements for identification distance or the application environment is more complicated, identification cards and base station receiving antennas with different signal strengths can be selected, and the receiving sensitivity of the base station can be adjusted by software to achieve the required identification distance.
Displacement speed
Using high-speed radio frequency identification technology, the identification speed is fast. When the maximum displacement speed of the identification card is 180km/h, it can still be reliably identified.
Concurrent identification number
Using a high-speed processor, combined with a variety of radio frequency anti-collision mechanisms, it can identify more than 500 identification cards at the same time, and the number of concurrent identifications is large. The miss rate is less than 10-4.
Communication security
Using a special communication protocol and address matching mechanism, coupled with a complete encryption algorithm, can ensure the security of data communication between the base station and the identification card, and prevent link detection and data cracking.
quality assurance
The production process is strictly controlled in accordance with ISO9000 quality standards to ensure product performance and quality.
Interface standard
The base station provides RJ45 and RS485 standard interfaces.
Flexible power supply
Support DC12V～48V, POE power supply, solar energy and other power supply methods.
typical application
The base station has a wide range of applications, including: the location and tracking of personnel and assets in the area, and access control management.
5.2 Electronic label
product description
The identification card is an active active identification card that works at 2.4GHz and transmits its own identification information regularly. It has the characteristics of long recognition distance, low power consumption, maintenance-free, stable and reliable performance. The label contains an excellent anti-collision mechanism, which is suitable for multi-label applications.
The identification card has the function of detecting the posture of the article, which can send out an alarm message when the posture of the article is moved or impacted; it also has a disassembly alarm function, which can send out an alarm message when the identification card is disassembled. It can be widely used in indoor asset management and other fields.
Structure
The shell adopts ultrasonic welding technology and cannot be disassembled. It is small in size, compact in structure, sturdy and durable, light in weight, and easy to carry, install and use.
shell material
Shell: Flame-retardant ABS engineering plastic.
technical parameter
Radio Frequency (2.4GHz)
Working frequency: 2.4GHz, 125KHz;
Transmission rate: 250kbps;
Transmitting power: ≤3dBm, adjustable;
Receiving sensitivity: -101dBm, adjustable;
Recognition distance:
The recognition distance with the BWBS series signal transceiver is as follows:
Omnidirectional antenna 120 meters (no obstruction in the air),
Directional antenna 300 meters (no obstruction in the air);
The recognition distances with BWPR series handheld readers are as follows:
Built-in antenna 50 meters (no obstruction in the air),
Omnidirectional antenna 120 meters (no obstruction in the air),
Directional antenna 300 meters (no obstruction in the air);
Recognition distance with BWLF series low frequency locator: 2～8 meters;
Working conditions
Electronic tags can work normally under the following conditions:
Working temperature: -20℃～60℃;
Average relative humidity: ≤95% (+25℃);
Atmospheric pressure: 80kPa～106 kPa;
Battery Life:
Replaceable battery identification card: 1 year
5.3 Positioner
Product Image
product description
The BWLF type locator (hereinafter referred to as the low-frequency locator) is an active transmitter that continuously sends 125KHZ low-frequency signals at a certain frequency. The signal includes its own number for distinguishing and identifying different locators.
If the identification card with low-frequency receiving function is not within the signal range of the low-frequency locator, the identification card is in the standby state. When the identification card enters the signal range of the low-frequency locator, it can automatically receive the low-frequency signal and analyze it.
Main Specifications
Working temperature: -20℃～60℃.
Storage temperature: -40℃～60℃
Working frequency: 125KHz.
Working voltage: AC220V.
Shell material: ABS engineering plastic
Environmental adaptability: Water-proof and shock-proof design, protection level reaches IP31.
Installation method: buried installation, top-mounted or side-mounted, fixed with screws, avoiding close to large areas of metal.
Detailed description
Operating mode
Low-frequency locator, the range of low-frequency signal is approximately spherical, with the transmitting antenna of the low-frequency locator as the center, and the theoretical signal radius is 2~8m.
The low-frequency locator has a multi-channel transmission function, which transmits radio frequency data every set time. The radio frequency data includes the number information of the low-frequency locator.
Recognition distance
In all kinds of barriers except metal barriers, and in the case of no barriers, it is 2m—8m; the identification card used to receive low-frequency signals is different, and the recognition distance is also different.
Installation requirements
The low-frequency positioner can be installed on the wall or on the ceiling. The low-frequency transmitting antenna can be led out and installed at the location where signal coverage is required (currently, the antenna extension line can be extended to 5m, and basically does not affect the signal radius of the antenna). The antenna can be fixed by screws or pasting.
Precautions for use
The locator antenna cannot be attached to metal, at least 2cm away from metal.
When in use, install the low-frequency locator on the wall or ceiling, and the low-frequency transmitting antenna is led out from the low-frequency locator housing through an extension cable and fixed in the range that needs low-frequency signal coverage. If you want to monitor the door, fix the antenna at the center of the side of the door. When a person wears an identification card that can receive low-frequency signals and passes through the door, the identification card can receive the locator number and upload the number via 2.4G. Therefore, it can be accurately determined that the wearer of the identification card appears near the doorway.
By analogy, two locator transmitting antennas can also be used to cover two doors, or inside and outside the door, to judge the entry and exit of the identity card wearer.
5.4 Product features
System advantages:
Can reliably identify fast-moving targets
Use AES encryption technology to encrypt the transmitted data to ensure the reliability and safety of data transmission
The positioning radio frequency card is small in size, easy to carry, install and hide
The transmitter power of the positioning radio frequency card is extremely low, which is safe for the human body
The base station is small in size, easy to install and maintain
Strong signal penetration and diffraction ability, high integration, good compatibility, simple and fast communication
The radio frequency card can adapt to various environments of -35℃～+60℃, and can be repeatedly disassembled and used
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