1 Company Profile

Shanghai Shucai IoT Technology Co., Ltd. is a high-tech enterprise focusing on IoT data collection. The company's core members have decades of rich project experience in the fields of industrial wireless sensors, factory instrument (electricity meter, flow meter, etc.) meter reading, equipment status monitoring, industrial equipment data cloud, etc. The company's core data collection products all support battery power supply, wireless transmission, and remote configuration and debugging. It eliminates the trouble of wiring, making on-site product installation and debugging extremely convenient, greatly shortening the project implementation cycle and cost.

The company currently operates and conducts business mainly in Pingdingshan, Henan. Adhering to the core concept of "technology is the root, quality is the basis, integrity and pragmatism, and pursuit of excellence", it is committed to building the company into a technology-based enterprise with first-class technology, first-class products and first-class services, and helping the rapid implementation of Internet of Things projects.

2 Project Background

Xinyang Huamao New Building Materials Co., Ltd., established in 2021 and located in Xinyang City, Henan Province, is a large-scale commercial concrete enterprise producing concrete materials .

Factory Photos

Factory situation: The concrete mixing plant is mainly composed of five systems, namely, the mixing main unit, material weighing system, material conveying system, material storage system and control system, combined with a high-level silo fully automatic feeding system. Compared with the aggregate metering of the concrete mixing plant, the aggregate metering of the concrete mixing plant reduces four intermediate links, and is a vertical material metering, which saves metering time, thus greatly improving production efficiency. Under the same model, the production efficiency of the mixing plant is one-third higher than that of the mixing station. Production line capacity: Theoretical data is 480 cubic meters per hour, the actual capacity is about 420 cubic meters per hour, and the annual output can reach 1 million cubic meters of concrete. Output products: meet the production of various formula specifications of concrete.

Sand production line production form: single machine dual control, fully automatic intelligent production system. ·Main structure: adopt steel-concrete structure, one layer of concrete structure, two layers and above steel structure, single silo 300 tons top. ·Functions realized: loader-free, automatic loading of high-level silos, environmental protection, energy saving and high efficiency. Fully automatic mixing building production line. ·Environmental protection requirements: The dust of the whole system is discharged in an organized manner, and the emission concentration is less than or equal to 10mg/Nm3. The noise meets the standards of environmental protection requirements, and the sound at a distance of 50 meters is not higher than 65 decibels. It can produce all series of ordinary mortar products, and can also produce a few special dry-mixed mortars. Small footprint, high production flexibility, environmental protection and energy saving, less dust. The equipment has strong anti-segregation ability. The energy consumption is lower than that of the traditional building type, and the cost performance is the highest. OJYVL300 sand and gravel co-export aggregate system adopts internationally advanced artificial dry sand making technology and core equipment crushing, the whole and other key technical equipment are at the leading level in the industry. The system adopts a modular combination structure, and the overall system structure is simple and scientific after optimized design. System features: Advanced and reliable sealing design, in line with environmental standards, large processing capacity. Scientific and reasonable process flow, low feed point design, meeting the processing requirements of materials of different specifications, industry-leading technical design. Optimized module combination design, compact overall design, high cost performance. Fully automatic control system, easy selection of product modulus coefficient preset mode. Stable product quality, meeting national sand making requirements.

3 Project demand research and analysis

Demand analysis: Energy consumption monitoring and real-time monitoring of the switch status of 20 sets of three-phase power distribution cabinets corresponding to key equipment such as commercial concrete line 1, commercial concrete line 2, dry-mixed mortar, machine-made sand line, machine-made brick production line, and high-level silos are carried out. The monitoring data is required to be connected to the upper-level ERP system, that is, the smart commercial concrete system.

Smart commercial concrete system interface

Distribution cabinet to be monitored

4 Project plan

According to the situation of the on-site power distribution cabinet, an electric energy monitoring instrument with an external open-type transformer is used, which is connected to the switch through the network port. The data is uploaded to the smart commercial concrete system at intervals of 1 minute. The protocol is MQTT and the data format is json.

According to the on-site investigation, different distribution cabinets have different rated currents, and they are monitored with current transformers of different ranges to obtain the most suitable installation size and accuracy.

Off-the-shelf equipment survey list

Ethernet Power Meter Kit

As shown in the figure above, the monitoring equipment consists of an ABS protective box, a rail power supply, a network port edge computing gateway, and a power monitor host. The rail power supply generates 12V power to power the edge computing grid. The power monitor host directly draws power from the 380V line.

Schematic diagram of project collection plan

5 Project Implementation

On-site construction photos

Project implementation steps:

1. Coordinate with the factory electrician to cut off the power supply to the distribution cabinet, select the monitored equipment, and install the transformer and monitoring host .

2. Install and secure the junction box.

remotely configures the edge computing gateway in the office .

4. Existing construction personnel submit an installation list, including installation point information, equipment IP information, number ID information, etc.

5. The whole project construction coordination lasted about a week to complete.

Installation effect diagram of power distribution cabinet for dry-mix mortar production line

Installation effect diagram of power distribution cabinet for high-level silo production line

Equipment installation effect diagram

Data collection is successfully stored in the cloud database

Factory energy consumption monitoring project data display screen

6 Project Outcomes

After the project is implemented, factory management and dispatching personnel can understand the on/off working status of each equipment in the workshop and the working energy consumption of key equipment in the office without leaving home. It is convenient to coordinate the production arrangements of each workshop production line from the overall production planning level, greatly improve the coordination efficiency, increase the equipment utilization rate, and produce more concrete products under the same energy consumption. It improves the overall economic benefits and the communication efficiency between the dispatching department and workshop personnel.