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1. System overview
The basic goal of the gas cylinder and retail safety management system is to use advanced RFID technology to realize the full-range management of the filling and circulation process of gas cylinders. A special-shaped logo is fixedly installed on each cylinder of the gas company through a dedicated method. Electronic tags for life-time identification of gas cylinders. This system covers not only the management of gas cylinders entering and leaving filling stations, gas exchange stations, and distribution links, but also the status and behavior of each process in the filling and testing process of gas cylinders. Take control to ensure the safety of gas cylinder circulation, eliminate hidden dangers of accidents, maintain the personal and property safety of enterprise employees, and prevent illegal users from making illegal profits.
Two, system goals
There may be various hidden dangers in the production and sales process of gas cylinders, which are mainly manifested in the related businesses of liquefied gas filling stations, gas cylinder maintenance companies and gas supply stations. The relevant business processes of these three can be improved through RFID. The details The goals are as follows:
2.1 LPG filling station
The production process of the filling station includes bottle collection, inspection, cleaning, weighing, bottle clearing, filling, inspection, sealing and shipping. At present, all generation links are manually inspected and detected, and there are problems of low efficiency and hidden dangers of errors. Through the RFID automatic identification technology, the identity of the gas cylinder can be quickly and accurately identified, which improves production efficiency, and at the same time prevents the gas cylinders to be inspected from flowing into the production link, causing hidden quality hazards.
2.2 Cylinder maintenance company
The production process of the gas cylinder maintenance company includes bottle collection, inspection, calcination, sand turning, painting, inspection and shipment. RFID technology can identify and record key process points, and finally realize the tracking and management of individual gas cylinders through the database.
2.3 Air supply station
The production process of the gas supply station includes bottle collection, gas exchange and door-to-door bottle delivery. The application of RFID in the gas station is used to register the gas cylinders entering and leaving the gas station to prevent other gas cylinders from entering the enterprise through the gas station channel.
3. System structure and authority
3.1 Cylinder identification and management
The only corresponding to the identification electronic tag of the industrial gas cylinder is a group of data information closely related to the gas cylinder. The label can be flexibly installed during installation, so that it can be removed and reinstalled during detection. The data in the label is stored through encryption, so the reinstalled label can be guaranteed to be the label of the system. Relevant enterprise operators can create files, edit and maintain this information through the system software. All operators and management personnel involved in the filling and circulation of gas cylinders can inquire part or all of the information through tag reading and writing equipment or management software according to their authority.
3.2 User identification and management
All users in the system are issued with readable and writable electronic tag user cards as the basis for identification and transaction. All users must first go to the company to go through the relevant procedures, receive the card and recharge. The delivery personnel send air to the door, confirm and deduct the corresponding amount of the user card through the tag handheld reading and writing device, and correspond the bottle number to it; or in the industrial gas station, the user can collect and return the gas bottle with the card, and the reading and writing device automatically judges the user card Whether it is legal and whether the number of gas cylinders on the card meets the requirements. When the conditions are met, the device automatically modifies the relevant information in the card, and the transaction data is immediately reported to the central management system.
3.3 Identification and management of operation personnel
Operators involved in system operations can be divided into the following categories:
(1)Industrial gas station receiving and dispatching management personnel
(2) Incoming management personnel of the filling station
(3) Cylinder inspection personnel
(4) Cylinder filling personnel
(5) Cylinder entry and exit management personnel
(6) Equipment inspection personnel
(7) System information management personnel
(8) Decision-making or corporate management personnel
(9) System management and maintenance personnel
For personnel of categories (1) to (6), the system will issue a unique user card for each employee, and the system will automatically determine the legality and authority of each employee and control their operations when they perform operations. After each operation is completed, the reading and writing device will report its identification code and operation information to the central management system of the system. So as to achieve real-time tracking and inspection of all personnel operations. For users of categories (7) to (9), the system directly checks the identity and authority by means of user name and user password.
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Figure 1 System structure diagram
Fourth, the system process
4.1 Production process of filling station based on RFID:
The implementation of RFID automatic identification technology will enable the filling station to establish visibility and information tracking of the gas bottle in all links of the production process from the first moment it receives the gas bottle.
The gas cylinder is unloaded from the transport vehicle, and the RFID reader placed in the channel will automatically recognize the Tag information on the gas cylinder and determine: 1) Combine the control device to determine whether there is a Tag? 2) Has the gas cylinder reached the overhaul period? The gas cylinders that need to be repaired will automatically enter the area to be repaired. This link will ensure that only the gas cylinders that meet the quality requirements of the company can enter the normal production process. The use of RFID will greatly improve the production efficiency of the gas cylinder inspection process, while also enabling accurate and error-free counting.
Before entering the filling workshop, re-read the tags of the gas cylinders through the channel-type reading device to confirm that the gas cylinders received this time have not been missed in the previous pre-filling process.
If necessary, RFID can be implemented at each station in the filling workshop to rewrite the tag information of the gas cylinder and write the information of the production inspector into the tag.
The RFID reading device is used at the exit of the filling workshop to ensure that the gas cylinders entering the workshop are filled within a certain time limit.
The loaded gas cylinders pass through the last RFID reading door channel, and the loading details of the gas cylinders will be automatically recorded.
4.2. RFID-based inspection station production process:
Since the RFID tag cannot withstand the high temperature of the calciner, we use the method of separating the tag from the bottle body to achieve it. The tracking of gas cylinders at this stage relies on the combination of the cylinder stamp, RFID Tag and database.
When the gas cylinder enters the inspection station, the data of the gas cylinder with the RFID tag will be automatically identified by the RFID reading device. If there is no tag, the steel stamp number will be recorded; if the device recognizes that the gas cylinder has exceeded the service life, the system will automatically alarm .
The gas cylinders that are still within the service life enter the maintenance process, and the sealed valve is removed. At the same time, the RFID Tag installed under the valve is also removed to wait for data information to be rewritten. At this point, the RFID tag is separated from the gas cylinder.
The rest of the gas cylinder maintenance process remains unchanged.
When the gas cylinder enters the valve sealing process, the staff in this process obtains the record of the cylinder from the database through the steel stamp on the cylinder, and writes the cylinder information into the RFID Tag through the RFID reader.
Since the tag can be rewritten, all tags can be used, and when the gas cylinder is overhauled and shipped out, the tag that represents the information of the gas cylinder is still carried.
Air supply station process:
After using RFID technology, the gas station will establish a connection with the local database through the RFID device.
When self-reporting customers change the gas cylinder, read the gas cylinder label to identify whether the air cylinder is the company’s property, and only the qualified gas cylinder can be replaced.
When receiving a new gas cylinder, the air supply personnel must read the tag information of the gas cylinder through RFID; when the old gas cylinder returns to the station, it also needs to read the old gas cylinder and establish a customer record in the database.
The RFID application of gas supply stations will help prevent foreign gas cylinders from flowing into corporate assets; it can help sites and companies establish work records of gas supply personnel; it can also help companies establish data records and sincere and loyalty analysis of LPG customers.
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Figure 2 Schematic diagram of gas cylinder filling and circulation process of gas cylinder safety management system
Five, system function
From a functional point of view, the system can achieve the following functions:
5.1 Data processing
The system has a data management center mainly for production, sales and storage of data, safety production and testing, supply chain data processing, and management of various business systems, and can alert illegal users and equipment. Use Portal technology to integrate the RFID system with the original video surveillance system. Achieve unified display.
5.2 Statistics management:
Perform dynamic statistics and management of gas cylinders entering and exiting filling stations and ventilation stations. With the support of special software, the handheld device communicates with the server of the industrial gas cylinder safety management system of the industrial gas company in real time. The operator can obtain the current gas according to his authority. Some basic information of the bottle. When there are various problems with the gas bottle, the handheld device will send out an alarm through sound and text, and the operator is required to take necessary treatment. At the same time, the server management software of the industrial gas cylinder logistics safety management system automatically modifies the status of the gas cylinders and registers relevant information at the same time. Basic information such as the entry and exit time of the gas cylinder, the operator and the whereabouts of the gas cylinder.
5.3 Management of filling plant (gas filling station)
The gas cylinder from the gas exchange station is cleaned, the relevant information on the label on the gas cylinder is read through the RFID read-write device deployed in the cleaning line, and the relevant information is submitted to the production management system to enter the gas filling link; bottle inspection is carried out before filling If there is a problem, enter the inspection link, if it is normal, enter the filling line after passing the inspection; after filling, use RFID equipment to conduct corresponding inspections, and all information in the filling process is submitted to the production line management system, which is carried out by the production line management system Corresponding treatment saves labor and time.
Carry out strict process tracking management for the circulation of gas cylinders in the gas station, and provide basic management processes such as pre-filling management, post-filling management, bottle inspection management, and warehouse entry and exit management. Real-time registration and strict judgment of the dynamic information of the gas cylinders flowing through each link, to prevent unqualified gas cylinders from entering the filling link, filling unqualified gas cylinders into storage and other behaviors that violate the normal circulation safety requirements.
5.4 Warehousing management of bottling plants
The gas cylinders in the warehouse are new bottles produced by the manufacturer and the bottles to be flushed returned by the user have a unique electronic tag to identify their identity and write corresponding information. The gas in the warehouse is read through the RFID read-write device deployed at the entrance. The number of cylinders and determine whether the cylinders are legal. Legal gas cylinders will enter the filling production line. If there is a problem with the gas cylinder, it will be sent to the bottle inspection program, the cylinder will be automatically set to the waiting state, and the gas cylinder will be locked by the system.
The filled steel cylinders are then sent to the warehouse, and the RFID equipment deployed on the production line is put into the warehouse for registration. When leaving the warehouse, use the RFID device to read the number of vehicles loaded, and write the corresponding information (such as delivery information) to load the vehicle, and automatically set the steel cylinder to the state of leaving the warehouse.
5.5 Management of distribution gas cylinder circulation
Mainly for the management of distribution stations and ventilating stations. As the store sales method gradually becomes a large-scale distribution method and the service deepens, this link will be more on-site for gas delivery in the future.
When the user returns the bottle, the RFID device can determine whether the gas bottle is a legal gas bottle. Under no abnormal conditions, modify the current circulation status of the gas cylinder to “at a ventilation station”. Then send it to the filling station. If there is a problem with the gas cylinder, the equipment starts to alarm and ask the operator to send the gas cylinder to the bottle inspection program. After the operator confirms, the cylinder is automatically set to the state to be inspected. In addition, if the incoming operator considers that it is necessary to inspect the steel cylinder based on actual judgment, the inspection can also be completed through the handheld device, and the steel cylinder will also be changed to a waiting state. If the cylinder enters the state to be inspected, the cylinder will be locked by the system before the registration of the inspection result is completed and the conclusion is qualified. If the steel cylinder is found at any link other than the bottle inspection, the reading and writing equipment will alarm and require the operator to deal with it.
Cylinders that pass the bottle inspection and do not require bottle inspection can enter the filling process. The desktop read-write device determines whether the user provides a valid user card and the user can withdraw the gas cylinder when the number of gas cylinders meets the conditions. The entry and exit of gas cylinders will be processed by reading and writing equipment at the exit and entrance, and data will be collected. If the air is delivered to the door and arrive at the user, the delivery personnel use the RFID handheld device to operate the gas cylinder label and change the information. If the user has used the electronic tag certificate, the delivery person can directly use the handheld device to debit the user card, and the data will be submitted to the data center through wireless means. If the conditions are not met, the delivery person can return to the delivery station or the ventilation station. Upload the data in the handheld device to the data center through the computer.
5.6 Inspection station management
The detection station mainly includes incineration, pressure measurement, leak detection, shot blasting, painting, etc. The high temperature of the incinerator will cause the damage of the label. The important thing in this link is to ensure the uniqueness of the gas cylinder information. This link can be passed The association of the information chain re-installs the label on the gas cylinder.
5.7 Equipment inspection
By installing special electronic tags on important equipment, equipment inspection management can be realized, equipment maintenance personnel are urged to conduct regular inspections, and the system automatically records their inspection behavior. If equipment maintenance personnel are found to be dereliction of duty, the system immediately informs relevant management personnel.
5.8 User Card Management
Management of ventilation customers through contactless cards. At the same time, it provides supporting functions such as card issuance, recharge, and card replacement.
5.9 Operator management
The operator’s identity is identified through non-contact cards, and the personnel and their operation behaviors are recorded in detail. When a problem occurs, it can maintain complete traceability to implement safety responsibilities to people.
5.1 Report output
The system provides various report output functions according to actual needs, and can quickly output necessary documents such as gas cylinder outbound orders, warehouse receipts, quality inspection notices, and scrap notices.
5.11 Query function
The system provides a complete combined query function, and the operator can quickly retrieve the data information and historical records of interest from the massive data according to various conditions.
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