Upgrading Scheme For The Old Sluice Automation Monitoring System
Publish Time: 2025-05-26
I. Project Background and Existing ChallengesThe original automation monitoring system of Meixi Bridge Sluice in Shantou City was put into operation in 2001. It consists of upper computers (industrial control computers, servers, offline management computers) and lower computers (PLC control cabinets, sensors). The software was developed based on the Windows 98 platform, using Rockwell RSView 32 configuration software and SQL 6.0 database, with hardware centered on PIII processor devices. After more than two decades of operation, the system faces two core issues:Outdated Architecture: The software and hardware heavily rely on obsolete platforms. The configuration software is out of warranty and incompatible with Windows 7/10 systems.Low Reliability: The industrial control computers enter a high-failure period after continuous operation (3-5 failures per year on average), and a single device failure can cause the entire system to collapse.II. Systematic Upgrading Scheme Design(A) Architectural Reconstruction: Layered Optimization with Core Asset RetentionContinued Use of Lower Computers: The original PLC control cabinets and sensors (such as water level meters and gate position meters) remain in use due to their stable performance, with only communication modules upgraded to adapt to new upper computers.Innovation in Upper Computers: Adopt a two-layer architecture of "Human Machine Interface (HMI) + data management platform (SQL)" to replace the traditional "industrial control computer + server" model, achieving decoupling of "control and management."(B) Core Upgrading Contents1. Human Machine Interface (HMI Touch Screen)Hardware Configuration: Deploy a 12-inch industrial-grade HMI with a quad-core processor, supporting Ethernet, RS485, and USB 3.0 interfaces, and built-in 2GB storage (expandable via SD card).Functional Upgrades:Real-time Monitoring: Dynamically display water level/gate position curves and equipment operation status, supporting remote start/stop and opening adjustment of gates.Intelligent Alarm: Built-in fault diagnosis logic automatically triggers audible-visual alarms.Local Storage: The SD card automatically backs up data, supporting 1-year historical data tracing.2. Data Management Layer (SQL Management System)Hardware Configuration: Commercial-grade monitoring and management computer (i5 processor + 128 GB SSD).Software Functions:Data Middleware: Regularly synchronize HMI data and automatically generate statistical indicators such as daily/weekly/monthly extreme water levels and gate operation frequencies.Report Engine: Built-in template library for one-click generation of water level trend charts and gate condition reports, supporting Excel/PDF export and customized design.III. Technological Innovations and Industry AdaptabilityLightweight Architecture Innovation: Break free from reliance on high-cost industrial control software in traditional SCADA systems. Use open-source configuration tools and universal SQL databases, reducing hardware costs by 60%.Offline Data Transmission Capability: The HMI supports offline storage of 7-day data, which automatically synchronizes to the SQL platform after network recovery, ensuring data integrity.Industry Applicability: The scheme has been validated at Meixi Bridge Sluice and is particularly suitable for small-to-medium-sized sluices (5-20 gates) that have been in operation for over 10 years and require a balance between cost and intelligence, such as irrigation district check gates and urban flood control sluices.Summary: The average fault-free operation cycle of the system is extended to 6 years, with data accuracy reaching 100%. Managers can real-time monitor sluice conditions within a 1-kilometer radius, helping water conservancy departments achieve the modern management goal of "minimum staffing and scientific scheduling."
