Unattended automatic metering system solution based on the Internet of Things
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1. Project background
As the basic production data and decision-making basis, the company’s material measurement provides a prerequisite guarantee for the company to achieve its development goals. Only the accurate, stable and rapid material measurement can better adjust the production capacity and varieties in time based on the corresponding purchase and sales data. , Inventory, thus playing a role in guiding production. Therefore, it is necessary for the informatization and automation construction of the measurement system to be consistent with the pace of the enterprise. It is precisely because of this market demand that the GAM (Goldbell Auomatic Measurement) unattended automatic measurement system appears, which not only solves the traditional measurement mode The existing data is not real-time, low degree of automation, easy to cheat, low measurement efficiency and other drawbacks, but also promote the integration of enterprise information and industrialization.
The unattended automatic metering system is composed of three parts: sensors, transmission network, and metering platform. These three elements coincide with the perception layer, network layer and application layer of the Internet of Things. The Internet of Things is the expanded application and network extension of the communication network and the Internet. It uses perception technology and smart devices to perceive and recognize the physical world, communicate through the network, perform calculations, processing and knowledge mining, and realize the information of people and things, things and things. Interactive and seamless connection to achieve real-time control of the physical world, precise management and scientific decision-making. The unattended automatic metering system measures the weight signal of the vehicle through the weighing sensor, and uses the wired or wireless network to transmit the measurement signal to the metering platform, and realizes the business reference of the data through the metering platform. Therefore, it can be said that the unattended automatic metering system is the Internet of Things A practical application that has been very successful in metering systems.
2. System characteristics
The GAM unattended automatic measurement system developed by Jinan Golden Bell Electronic Weighing Apparatus Co., Ltd. has aroused strong market response since its inception. Based on the application of the Internet of Things, the system integrates multiple technologies such as automatic detection, streaming media, pattern recognition, information processing, and computer networks. The data resource sharing of sales and management departments can further strengthen internal management of the enterprise, effectively plug various management loopholes, and realize the network and electronic business handling process, and provide reliable and timely basis for the decision-making of user leaders. After the system has been applied to various industries, it has received good economic and social benefits, which fully embodies the real-time, accurate and efficient characteristics of weighing instruments, and has become a demonstration product for the application of Internet of Things technology in the weighing industry.
The unattended automatic metering system has the following characteristics:
1. Improve the measurement efficiency, and shorten the measurement time of a single vehicle from the original 3 to 4 minutes to 15 to 30 seconds;
2. The whole measurement process is completed automatically, without manual interference, realizing truly unattended;
3. There is no need for weighing houses on the new metering project site, which reduces infrastructure investment and can save a lot of operating costs;
4. Reasonably allocate and dispatch the use load of the weighing instrument, tap and play the maximum efficiency of the existing weighing instrument of the enterprise per unit time;
5. Adopt various anti-cheating methods such as human scale separation, historical tare curve comparison, infrared limit, real-time monitoring, and image capture;
6. 24-hour real-time monitoring of the operating status of sensors and instruments, and automatic alarms when abnormalities occur;
7. Establish a variety of system emergency plans to ensure that the system can achieve uninterrupted measurement under abnormal conditions;
8. Independent subsystem, which can be integrated with ERP, MES and other management systems to avoid repeated investment in information construction;
9. The system is modularized, and functions can be tailored according to customer needs to achieve rapid integration.
Three, system design and implementation
1. Design Ideas
Establish an independent metering system and logistics management platform to realize automatic, self-service, and remote metering, use IC cards as the carrier of information transmission, establish door guards, receiving and shipping confirmation terminals, and close-loop control of the vehicle metering business to ensure every metering business And logistics control can be carried out in accordance with the prescribed process and path, and can be seamlessly connected with the existing ERP system.
The unmanned automatic measurement system has aroused strong market response since its inception. The system is based on RFID identification technology and integrates multiple technologies such as automatic detection, streaming media, pattern recognition, information processing and computer networks. The data resource sharing of sales and management departments can further strengthen internal management of the enterprise, effectively plug various management loopholes, and realize the network and electronic business handling process, and provide reliable and timely basis for the decision-making of user leaders. After the system has been applied to various industries, it has received good economic and social benefits, which fully embodies the real-time, accurate and efficient characteristics of weighing instruments, and has become a demonstration product for the application of Internet of Things technology in the weighing industry.
2. System Architecture
This system is designed in accordance with the remote metering system concept of “self-service metering + remote metering + centralized monitoring”. The entire system adopts the design mode of centralized management and distributed monitoring. All business data (data, voice, image, control signal, etc.) pass through unmanned The guard machine (terminal) and the software system perform on-site processing, and interact with the control center through the metering dedicated optical fiber network and the video monitoring network. The system network also covers various logistics, product warehouses and energy monitoring sites, realizing the unified scheduling management of the company’s metering, business, and other aspects.
The system design adopts a three-tier C/S architecture: data base layer, data management layer, and business application layer.
Data base layer—each metering site
The basic data of each metering station includes the weight data reading of the meter, the audio and video signal collection of the surveillance camera, the infrared monitoring signal collection, the interaction of the voice intercom signal, the information collection of the IC card and the RFID card, the command control of the meter status, etc. As the data support for system operation, the basic data layer adopts a mode design combining local control and remote control to improve the reliability of system operation.
Data management layer-measurement monitoring center server group
The metering center server is the core hub of the entire system, responsible for the management, operation, control, and interaction with the information system and other business systems of the entire metering system. Servers include database servers, application servers, task management servers, video management servers, centralized image storage management servers, etc.
Business application layer-remote metering workstations and business stations
Each meter in the monitoring center is authorized to use the business application system to realize remote metering business operations and remote metering monitoring. In the lobby of the metrology center, a remote metering terminal seat is set up to be responsible for remote metering monitoring; a metering dispatch terminal is set up to be responsible for metering task distribution and global metering monitoring; a monitor video wall and LED screen are set up to monitor the global metering logistics situation. Each business station also includes card issuing station, guard station, card issuing station, material yard station, warehouse station, quality inspection station, etc.
3. Measuring point data collection terminal
Each metering point is equipped with a data collection terminal, namely a GAM machine, which integrates embedded industrial-grade controllers, intelligent voice intercom, printing units, smart IC card readers, RFID controllers, smart collection units, UPS power supplies and other equipment.
Industrial-grade embedded control host is adopted, which has the characteristics of low power consumption, high reliability, and high stability. At the same time, it adopts embedded operating system, multi-tasking and multi-threading to ensure the strong real-time performance of the system; internal industrial switches and optical networks Interface, high-speed and stable data exchange, and at the same time can control the port, IP address, speed, etc., configure the network to the optimal state; intelligent instrument status and real-time sensor monitoring and control functions, monitoring the work of the metering instrument through the remote system Status, the value and status of each sensor can be remotely cleared and controlled by the instrument; embedded smart card reader function, through the embedded smart card reader, you can quickly read and write IC cards, and the card is embedded in the reader To prevent the mobile card from malfunctioning when writing information, set an emergency button to ensure the normal extraction of the IC card. After the card is written, the system will perform quick verification to ensure the correctness and completeness of the card; read the RFID smart tag, post an RFID tag on the upper right corner of the vehicle, the ID number in the tag is a unique label, and the label and the vehicle number are one by one Binding, for vehicles in the factory fleet, RFID card management can be implemented to achieve fast and efficient logistics operations.
4. Realization of network layer software and hardware
The network adopts the C/S+B/S model, and according to the application needs, it can adopt the public communication network or the industry private network, or even build a new communication network dedicated to the Internet of Things. Users can set up a wired optical fiber network covering all metering points and business points of the system, or they can connect through wireless communication. At present, the wireless basically adopts new foreign technologies such as IEEE802.15.4 and WLAN. The domestic 2G/3G wireless network access is enhanced, and IP Bearer and network transmission technologies have also achieved great results. Through cooperation with telecom operators, the limitations of wired networking can be easily broken.
Application terminal
The system uses the C# development language of the .NET development platform and Oracle or SQL database management system. The server is based on the windows2008server operating system, which is convenient for remote network deployment, management and use. The infrastructure is safe and has strong reliability and scalability. The XP operating system is selected for the metering operation terminal, which can be compatible with a variety of applications.
5. Application layer design
The application layer is the interface between the system and users (including people, organizations and other systems). It combines with industry needs to truly realize the intelligent application of the Internet of Things. The main man-machine interface functions of this system are as follows:
Automatic measurement management sub-module
Sensor data monitoring sub-module
Scheduling management sub-module
Smart card management sub-module
Access control management sub-module
Warehouse receipt and delivery management sub-module
Video surveillance management sub-module
Four, project application
At present, the project has been practically applied in Jinan Iron and Steel, Wuyang Iron and Steel, and Nanjing Iron and Steel. It has solved the shortcomings and disadvantages of traditional measurement methods, and has improved the level of enterprise informatization. At the same time, it has also created the company’s service brand and increased its visibility.
V. Project conclusion
In short, the successful application of the Internet of Things technology in the remote unattended automatic measurement system fully demonstrates that the Internet of Things technology is an important engine to change the development mode of the weighing industry. As a breakthrough direction of measurement technology, the Internet of Things contains huge growth potential. It enables real-time, accurate and effective use of weighing measurement. With the continuous development of perception recognition, intelligent processing technology and network communication technology, the establishment of the standardization of the core architecture of the Internet of Things to the interfaces of all layers, and the support of government enterprises at all levels, the Internet of Things technology will surely be successfully applied in more industries and promote vigorously. The deep integration of informatization and industrialization has caused major changes in the economic structure adjustment and development mode of domestic enterprises.
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