CN104392582A - Remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion - Google Patents

Abstract

The invention discloses a ship welder remote monitoring and alarming system based on multi-sensor information fusion, which comprises a welder safety helmet, a Zgibee on-chip system integrated with a single-chip microcomputer inner core, a photosensitive sensor and interface circuit, a reflective infrared photoelectric sensor and interface circuit, a three-axis acceleration sensor, a reflector plate, a first light shielding plate, a second light shielding plate goggles, a handheld face shield and a Zigbee module. The safety helmet has a reasonable structure, and can timely and accurately judge whether a practitioner uses the welding hand-held mask or goggles, whether the practitioner wears the safety helmet or whether the practitioner falls down.

Description

Remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion

technical field

The invention relates to a monitoring system, which is a remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion.

Background technique

The shipbuilding industry is a labor-intensive and technology-intensive industry. In hull construction, welding man-hours account for about 30% to 40% of the total man-hours of hull construction, and welding costs account for 30%-50% of the total cost of hull construction. The welding workload of ships is very large. The butt weld seam of 10,000-ton oil tanker is about 20KM; the butt weld seam of 100,000-ton oil tanker is about 50KM; The weld seam is about 30KM long.

Most of the welding in ship repairing and building in my country is manual welding. In 2012, scholars from Peking University and other institutions (Xu Yan, Gong Manman, Wang Jiao et al. Survey on current situation of welding ultraviolet radiation hazards to workers and protective measures[J]. Journal of Peking University ( Medical Edition), 2012, 44 (3): 448-453) conducted a survey on the hazards of welding ultraviolet radiation to workers. A total of 828 valid questionnaires were obtained, including 721 welders and 107 assistant workers. The incidence of symptoms and signs of facial skin injury from high to low is burning and tingling (48.7%), skin itching (39%), pigmentation (31.9%), skin flushing (25.4%), and numbness (12%) ), maculopapular (10.1%), verrucous vegetation (3.7%). Among the surveyed workers, 90% had electro-optic ophthalmia in the past year, and the symptoms of eye injury in descending order of incidence were eye pain (61.5%), photophobia and tearing (61.4%) , blurred vision (50.2%), burning sensation (35.9%), foreign body sensation (32%), and eye twitching (12.2%). The incidence of lens opacity was found to be 15.8% in the eye examination of 438 workers, and the occurrence of fundus lesions The rate is 2.5%.

Welder electro-optic ophthalmia caused by welding arc is listed as the second largest occupational disease after pneumoconiosis. The risk of not wearing a protective mask is 1.8 times that of wearing a protective mask. In the occasion where many people are welding at the same time, Personnel not engaged in welding operations are also vulnerable to damage from surrounding arc radiation. In shipbuilding companies, welding without goggles or welding masks frequently occurs. Arc light and splashes cause visual damage, skin tissue damage and even skin cancer, which seriously affects health and work efficiency. Such violations of welding safety management regulations and indifferent protection awareness must be effectively monitored and managed to prevent health injuries caused by them.

Contents of the invention

The purpose of the present invention is to provide a remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion that has a reasonable structure and can promptly and accurately judge whether the practitioner uses a welding hand mask or goggles, wears a safety helmet, or falls.

Technical solution of the present invention is:

A remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion is characterized in that it includes welding helmets, a Zgibee system-on-chip integrated with a single-chip microcomputer core, a photosensitive sensor and an interface circuit, a reflective infrared photoelectric sensor and an interface circuit, Three-axis acceleration sensor, reflector, first shading plate, second shading plate goggles, hand-held mask, Zigbee module; Zigbee system-on-chip integrated with single-chip microcomputer core, photosensitive sensor and interface circuit, reflective infrared photoelectric sensor and interface The circuit, the first shading plate, and the three-axis acceleration sensor are all installed on the helmet of the welding personnel; the integrated single-chip microcomputer core Zigbee system on chip, the interface circuit of the photosensitive sensor, the interface circuit of the reflective infrared photoelectric sensor, and the three-axis acceleration sensor are all installed on the helmet of the welding personnel. Inside the helmet; the photosensitive sensor, reflective infrared photoelectric sensor, and the first shading plate are fixedly installed on the outer surface of the welder's helmet; when the welder puts on the helmet, the photosensitive sensor should be located directly in front of the welder and can sense the distance in front of the welder. External light intensity; when the welder puts on the safety helmet and goggles, the reflective infrared photoelectric sensor is located directly in front, and the emission tube points to the goggles; the first shading plate is fixedly installed in front of the reflective infrared photoelectric sensor, and its length is longer than that of the reflective infrared photoelectric sensor. Infrared photoelectric sensor to ensure that the light source in front of the welder will not interfere with the infrared photoelectric sensor; if the welder wears goggles as a protective device, the upper surface of the goggles is opposite to the infrared photoelectric sensor, and a reflective sheet is attached, and the second shading plate is fixed and installed In front of the reflector, ensure that the light source in front of the welding personnel will not be reflected by the reflector to the infrared photoelectric sensor; a Zigbee communication module is placed at the door of the cabin, which is responsible for outputting the information transmitted by the Zigbee system on chip in the helmet to the monitoring room through the wireless network .

The Zigbee system-on-chip adopts the CC2530 chip, which contains a single-chip microcomputer with 51 cores.

Welding start and helmet wearing detection process:

The single-chip microcomputer in the Zigbee system on a chip receives the signal of the photosensitive sensor to confirm that the welding starts. After the single-chip microcomputer confirms that the welding starts, it first detects whether the welding personnel wear a safety helmet. The confirmation method is as follows: each welder wears a fixed helmet, and the identity information of the person is solidified in the single-chip microcomputer; and there is a three-axis acceleration sensor inside the helmet; if the person does not wear a helmet, the helmet position information, attitude The information will not change; if the person wears a safety helmet, the posture change of the human head during the operation will cause the sensor to output information. Since the three-axis acceleration sensor is used, the head shaking will cause the sensor output; because the welding operator does not It may be completely still, so when the person wears the safety helmet, the information output by the triaxial acceleration sensor is constantly changing; If there is no change, it can be considered that the corresponding welding personnel are not wearing safety helmets;

After the single-chip microcomputer confirms that the welding starts, it collects the information of the three-axis acceleration sensor; the three-axis acceleration sensor can input X, Y, Z three-way analog or digital signals. If the analog signal is output, it will be sent to the A/D of the chip. If the output digital signal can be directly connected to the single-chip microcomputer; the single-chip microcomputer collects the three-channel data of the three-axis acceleration sensor every once in a while. The single-chip microcomputer sets the counter through the software to calculate the number of times the single-chip microcomputer collects the data of the three-axis acceleration sensor. If the three-way data does not change after reaching the set number of times, it can be considered that the corresponding welder does not wear a helmet; the single-chip microcomputer sends the identity of the person through the zigbee network Information, character information representing that the person is not wearing a safety helmet, and a remote alarm is issued, which is recorded and managed by the monitoring room; if it is found that the data change rate of any channel of the triaxial acceleration sensor exceeds the threshold set manually, it can be determined that the person may If you fall, alarm, record and manage through zigbee;

At the entrance and exit of each cabin, a Zigbee communication module is installed. As a relay node, the single-chip microcomputer of the Zigbee system-on-chip in the helmet transmits the alarm information to the Zigbee communication module at the entrance and exit of the cabin, and the communication module uploads the signal layer by layer until General monitoring room.

Handheld mask or goggles inspection process:

In welding, welders use hand-held masks or wear goggles for arc protection;

After confirming that the welder wears the safety helmet, the MCU software delays, and then reads the photosensitive sensor information after the MCU software delays. If the photosensitive sensor no longer feels the arc light, it means that the welder has picked up the mask to block the solitary light. Transmission to photosensitive sensor;

If the photosensitive sensor can feel the arc light after the MCU is delayed, there may be two situations: one is that the welder does not use a hand-held mask, but uses goggles; the other is that the welder neither uses a hand-held mask nor uses goggles ; Therefore, the next step is to detect the goggles; the reflective infrared photoelectric sensor emission tube installed on the safety helmet points to the bridge of the welder's nose, and a reflector is pasted on the surface of the goggles above the bridge of the nose. If the welder wears goggles, then The reflective infrared photoelectric sensor receiving tube can receive the reflected infrared light; if the welder does not wear goggles, the reflective infrared photoelectric sensor receiving tube cannot receive enough light intensity; in order to avoid arc interference, the reflective infrared photoelectric sensor , Reflectors, all fixedly install the light baffle; the single-chip microcomputer drives the reflective infrared photoelectric sensor emission tube through the modulation mode; the infrared receiving tube is connected to the single-chip microcomputer through the interface circuit, and the single-chip microcomputer detects the reflection signal with a frequency of f through the software, thereby increasing the system Anti-interference ability;

When the single-chip microcomputer continuously detects the response of the photosensitive sensor, but does not detect the response of the reflective infrared sensor, it can be determined that the welder is using both a hand-held mask and no goggles, and the single-chip microcomputer of the Zigbee system-on-chip in the helmet will identify the welder ;, The alarm information is transmitted to the Zigbee communication module at the entrance and exit of the cabin, and the communication module uploads the signal layer by layer to the general monitoring room for recording and management.

The invention adopts a new type of monitoring system for two kinds of welding protection products, hand-held masks and goggles. Through multi-sensor comprehensive detection, it is judged whether the practitioners use welding hand-held masks or goggles, whether they wear safety helmets, and whether they have fallen. If the welding mask or goggles are not used as required, and the safety helmet is not worn, the corresponding identity code (such as job number) and illegal operation information of the person will be sent to the monitoring room, and the alarm will be sent to the safety monitoring personnel for recording and management.

The beneficial effects of the remote safety monitoring and alarm system for shipbuilding and welding personnel based on multi-sensor information fusion in the present invention are mainly manifested in:

Versatile. Monitoring the most commonly used safety helmets, hand-held masks, and goggles in shipbuilding and welding can effectively monitor the illegal operations of welding personnel who do not wear safety helmets, welding masks or goggles when they are working. And it can monitor the falling state of welding personnel.

Low cost and strong function. Use cheap photoelectric sensors. Adopt Zigbee networking mode to realize remote transmission of information. A Zigbee system-on-chip with a single-chip microcomputer core is used to realize information processing. It has high cost performance.

High degree of intelligence. Infrared photoelectric sensors, photosensitive sensors, and triaxial acceleration sensors are used for detection. Through comprehensive analysis of multi-sensor information, the safety protection equipment worn by welders during welding is obtained.

Description of drawings

The present invention will be further described below in conjunction with drawings and embodiments.

Fig. 1 is a block diagram of a remote safety monitoring and alarm system for shipbuilding and welding personnel of the present invention;

Fig. 2 is a program flow chart of the remote safety monitoring and alarm system for shipbuilding and welding personnel according to the present invention.

Detailed ways

The present invention will be further described below in conjunction with the accompanying drawings.

A remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion, which is mainly composed of the following parts (refer to Figure 1): welding personnel helmet 1, Zgibee system on chip (integrated with a single-chip microcomputer core) 2, photosensitive sensor 3 and Interface circuit 4, reflective infrared photoelectric sensor 5 and interface circuit 6, triaxial acceleration sensor 7, reflector 8, first shading plate 9, second shading plate 10, goggles 11, hand-held mask 12, Zigbee module 13. Zigbee system-on-chip (integrated with single-chip microcomputer core), photosensitive sensor and interface circuit, reflective infrared photoelectric sensor and interface circuit, light shield 1, and three-axis acceleration sensor are all installed on the welding helmet. Among them, the Zigbee system on chip (integrated with a single-chip microcomputer core), the photosensitive sensor interface circuit, the reflective infrared photoelectric sensor interface circuit, and the three-axis acceleration sensor are all installed in the welding helmet. The photosensitive sensor, reflective infrared photoelectric sensor, and light shielding plate 1 are fixedly installed outside the welder's safety helmet. When the welder puts on the safety helmet, the photosensitive sensor should be located directly in front of the welder, which can sense the external light intensity in front of the welder. When the welder puts on the safety helmet and goggles, the reflective infrared photoelectric sensor is located directly in front, and the emission tube points to the goggles. The first shading plate is fixedly installed in front of the reflective infrared photoelectric sensor, and its length should be longer than that of the reflective infrared photoelectric sensor, so as to ensure that the light source in front of the welder will not interfere with the infrared photoelectric sensor. If welding personnel wear goggles as protective equipment, the upper surface of the goggles is opposite to the infrared photoelectric sensor, and a reflective sheet is pasted, and the second light shield is fixedly installed in front of the reflective sheet to ensure that the light source in front of the welder will not be reflected by the reflective sheet. Infrared photoelectric sensor. Since the cabin is mostly a closed space with a metal structure, in order to overcome signal shielding and enable remote transmission of information, a Zigbee communication module is placed at the door of the cabin, which is responsible for outputting the information transmitted by the Zigbee system-on-chip in the helmet to the monitoring room through a wireless network.

The Zigbee system on chip (integrated with the single-chip microcomputer core), the photosensitive sensor interface circuit, the reflective infrared photoelectric sensor interface circuit, and the three-axis acceleration sensor are all installed in the helmet of the welding personnel, and the specific installation position is located in the gap between the top of the personnel's head and the top shell of the helmet. After the welder puts on the safety helmet, it is necessary to ensure that the photosensitive sensor is located directly in front and can sense the external light intensity. The reflective infrared photoelectric sensor is also located directly in front, and the emitted infrared light points to the bridge of the welder's nose.

When the welding starts, the photosensitive sensor senses a strong arc, and the interface circuit generates a signal change, which is input to the core single-chip microcomputer of the Zigbee system-on-chip. The Zigbee system-on-chip can use CC2530 and other chips, which contain a single-chip microcomputer with 51 cores.

Welding start and helmet wearing detection:

The single-chip microcomputer (hereinafter referred to as the single-chip microcomputer) in the Zigbee system on a chip receives the signal of the photosensitive sensor and confirms that the welding starts. After the single-chip microcomputer confirms that the welding starts, it first detects whether the welding personnel wear a safety helmet. The confirmation method is as follows: each welder wears a fixed safety helmet, the identity information of the person (such as the job number) is solidified in the single-chip microcomputer, and there is a three-axis acceleration sensor inside the safety helmet. If the person does not wear a helmet, the helmet position information and attitude information will not change. If the person wears a safety helmet, the posture change of the human head during the operation will cause the sensor to output information. Due to the selection of a high-sensitivity three-axis acceleration sensor, even a slight head shake will cause the sensor output. Since the welding operator cannot be completely still, when the personnel put on the safety helmet, the information output by the three-axis acceleration sensor is constantly changing. Therefore, the single-chip microcomputer can be used to collect the triaxial acceleration sensor signal in real time. If it is found that the information of the three channels of the triaxial acceleration sensor has not changed for a period of time, it can be considered that the corresponding welder is not wearing a safety helmet.

After the single-chip microcomputer confirms that the welding starts, it collects the information of the three-axis acceleration sensor. The three-axis acceleration sensor can input X, Y, Z three-way analog or digital signals. If it outputs an analog signal, it will be sent to the A/D port of CC2530. If it outputs a digital signal, it can be directly connected to the microcontroller. The single-chip microcomputer collects the three-channel data of the three-axis acceleration sensor at intervals (the time interval is in milliseconds). The single-chip microcomputer sets the counter through the software to calculate the number of times the single-chip microcomputer collects the data of the three-axis acceleration sensor. If the three-way data does not change after reaching the set number of times (such as 10 times), it can be considered that the corresponding welder is not wearing a helmet. The single-chip microcomputer sends out the identity information of the person through the zigbee network, character information representing that the person does not wear a helmet, and performs remote alarming, which is recorded and managed by the monitoring room. If it is found that the data change rate of any channel of the three-axis acceleration sensor exceeds the threshold value set manually, it can be determined that the person may fall, and the alarm, record and management will also be carried out through zigbee. This method can monitor unexpected situations such as electric shocks for welding personnel. Rescue buys time.

Since the cabin is mostly a metal structure, it has a strong shielding effect on the signal. Therefore, at the entrance and exit of each cabin, a Zigbee communication module is installed. As a relay node, the single-chip microcomputer of the Zigbee system-on-chip in the helmet transmits the alarm information to the Zigbee communication module at the entrance and exit of the cabin, and the signal is uploaded layer by layer by the communication module until General monitoring room.

Handheld mask or goggle detection:

In welding, welders generally use hand-held masks or wear goggles for arc protection.

After confirming that the welder wears the safety helmet, the MCU software delays (it takes a short time for the welder to grab the mask after striking the arc). After the single-chip software delays, it reads the information of the photosensitive sensor. If the photosensitive sensor no longer feels the arc light, it means that the welder has picked up the mask to block the solitary light from being transmitted to the photosensitive sensor.

If the photosensitive sensor can still feel the arc light after the delay of the single chip microcomputer, there may be two situations: one is that the welder does not use a hand-held mask, but uses goggles. The second is that the welders did not use either hand-held masks or goggles. So in the next step, goggle detection will be performed. The reflective infrared photoelectric sensor emission tube installed on the safety helmet points to the nose bridge of the welder. On the surface of the goggles above the bridge of the nose, a reflective sheet is pasted. If the welder wears goggles, the reflective infrared electric sensor receiving tube can receive reflected infrared light. If the welder does not wear goggles, the receiver tube of the reflective infrared photoelectric sensor cannot receive enough light intensity. In order to avoid arc light interference, light baffles are fixedly installed at the reflective infrared photoelectric sensor and reflector. The single-chip microcomputer drives the reflective infrared photoelectric sensor emission tube through the modulation mode (set the modulation frequency as f), the infrared receiving tube is connected to the single-chip microcomputer through the interface circuit, and the single-chip microcomputer detects the reflected signal with the frequency f through the software, thereby increasing the anti-interference ability of the system.

When the single-chip microcomputer continuously detects the response of the photosensitive sensor, but does not detect the response of the reflective infrared sensor, it can be determined that the welder is using both a hand-held mask and no goggles, and the single-chip microcomputer of the Zigbee system-on-chip in the helmet will identify the welder (job number) and alarm information are transmitted to the Zigbee communication module at the entrance and exit of the cabin, and the communication module uploads the signal layer by layer to the general monitoring room for recording and management.

Claims (4)

1. A remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion, characterized in that it includes a welding personnel helmet, a Zgibee system-on-chip integrated with a single-chip microcomputer core, a photosensitive sensor and an interface circuit, a reflective infrared photoelectric sensor and an interface Circuit, three-axis acceleration sensor, reflector, first shading plate, second shading plate goggles, hand-held mask, Zigbee module; Zigbee system-on-chip integrated with single-chip microcomputer core, photosensitive sensor and interface circuit, reflective infrared photoelectric sensor And the interface circuit, the first shading plate, and the three-axis acceleration sensor are all installed on the helmet of the welding personnel; the integrated single-chip microcomputer core Zigbee system on chip, the photosensitive sensor interface circuit, the reflective infrared photoelectric sensor interface circuit, and the three-axis acceleration sensor are all installed on the Inside the welding personnel's helmet; the photosensitive sensor, reflective infrared photoelectric sensor, and the first shading plate are fixedly installed on the outer surface of the welding personnel's helmet; when the welding personnel puts on the helmet, the photosensitive sensor should be located directly in front of the welding personnel to sense The external light intensity in the front; when the welder puts on the safety helmet and goggles, the reflective infrared photoelectric sensor is located directly in front, and the emission tube points to the goggles; the first shading plate is fixedly installed in front of the reflective infrared photoelectric sensor, and the length Longer than the reflective infrared photoelectric sensor, to ensure that the light source in front of the welder will not interfere with the infrared photoelectric sensor; if the welder wears goggles as protective equipment, the upper surface of the goggles is opposite to the infrared photoelectric sensor, and a reflective sheet is attached, and the second shading plate It is fixedly installed in front of the reflector to ensure that the light source in front of the welder will not be reflected by the reflector to the infrared photoelectric sensor; a Zigbee communication module is placed at the door of the cabin, which is responsible for outputting the information transmitted by the Zigbee system-on-chip in the helmet to the monitoring room. 2. The remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion according to claim 1 is characterized in that: the Zigbee system-on-chip adopts the chip of the CC2530 model, and contains a single-chip microcomputer with 51 cores. 3. The remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion according to claim 1 or 2, characterized in that: welding start and safety helmet wearing detection process: The single-chip microcomputer in the Zigbee system on a chip receives the signal of the photosensitive sensor to confirm that the welding starts. After the single-chip microcomputer confirms that the welding starts, it first detects whether the welding personnel wear a safety helmet. The confirmation method is as follows: each welder wears a fixed helmet, and the identity information of the person is solidified in the single-chip microcomputer; and there is a three-axis acceleration sensor inside the helmet; if the person does not wear a helmet, the helmet position information, attitude The information will not change; if the person wears a safety helmet, the posture change of the human head during the operation will cause the sensor to output information. Since the three-axis acceleration sensor is used, the head shaking will cause the sensor output; because the welding operator does not It may be completely still, so when the person wears the safety helmet, the information output by the triaxial acceleration sensor is constantly changing; If there is no change, it can be considered that the corresponding welding personnel are not wearing safety helmets; After the single-chip microcomputer confirms that the welding starts, it collects the information of the three-axis acceleration sensor; the three-axis acceleration sensor can input X, Y, Z three-way analog or digital signals. If the analog signal is output, it will be sent to the A/D of the chip. If the output digital signal can be directly connected to the single-chip microcomputer; the single-chip microcomputer collects the three-channel data of the three-axis acceleration sensor every once in a while. The single-chip microcomputer sets the counter through the software to calculate the number of times the single-chip microcomputer collects the data of the three-axis acceleration sensor. If the three-way data does not change after reaching the set number of times, it can be considered that the corresponding welder does not wear a helmet; the single-chip microcomputer sends the identity of the person through the zigbee network Information, character information representing that the person is not wearing a safety helmet, and a remote alarm is issued, which is recorded and managed by the monitoring room; if it is found that the data change rate of any channel of the triaxial acceleration sensor exceeds the threshold set manually, it can be determined that the person may If you fall, alarm, record and manage through zigbee; At the entrance and exit of each cabin, a Zigbee communication module is installed. As a relay node, the single-chip microcomputer of the Zigbee system-on-chip in the helmet transmits the alarm information to the Zigbee communication module at the entrance and exit of the cabin, and the communication module uploads the signal layer by layer until General monitoring room. 4. The remote monitoring and alarm system for ship welding personnel based on multi-sensor information fusion according to claim 1 or 2, characterized in that: the detection process of hand-held masks or goggles: In welding, welders use hand-held masks or wear goggles for arc protection; After confirming that the welder wears the safety helmet, the MCU software delays, and then reads the photosensitive sensor information after the MCU software delays. If the photosensitive sensor no longer feels the arc light, it means that the welder has picked up the mask to block the solitary light. Transmission to photosensitive sensor; If the photosensitive sensor can feel the arc light after the MCU is delayed, there may be two situations: one is that the welder does not use a hand-held mask, but uses goggles; the other is that the welder neither uses a hand-held mask nor uses goggles ; Therefore, the next step is to detect the goggles; the reflective infrared photoelectric sensor emission tube installed on the safety helmet points to the bridge of the welder's nose, and a reflector is pasted on the surface of the goggles above the bridge of the nose. If the welder wears goggles, then The reflective infrared photoelectric sensor receiving tube can receive the reflected infrared light; if the welder does not wear goggles, the reflective infrared photoelectric sensor receiving tube cannot receive enough light intensity; in order to avoid arc interference, the reflective infrared photoelectric sensor , Reflectors, all fixedly install the light baffle; the single-chip microcomputer drives the reflective infrared photoelectric sensor emission tube through the modulation mode; the infrared receiving tube is connected to the single-chip microcomputer through the interface circuit, and the single-chip microcomputer detects the reflection signal with a frequency of f through the software, thereby increasing the system Anti-interference ability; When the single-chip microcomputer continuously detects the response of the photosensitive sensor, but does not detect the response of the reflective infrared sensor, it can be determined that the welder is using both a hand-held mask and no goggles, and the single-chip microcomputer of the Zigbee system-on-chip in the helmet will identify the welder ;, The alarm information is transmitted to the Zigbee communication module at the entrance and exit of the cabin, and the communication module uploads the signal layer by layer to the general monitoring room for recording and management.