Design of an Industrial Ethernet-based Remote Data Acquisition System
2026-04-06 07:45:13··#1
Abstract: Industrial Ethernet ring network technology and advanced control technology are applied to coal mine data acquisition systems, forming a new generation of coal mine SCADA systems. This paper presents its structural composition, functions of each component, and software design. The entire system not only achieves rapid information transmission but also realizes the safety early warning function of coal mines. Keywords: Data acquisition; Industrial Ethernet; Remote data transmission; Ring network 1 Introduction With the development of science and technology, the scale of coal mine production is constantly expanding, and the number of electrical equipment is also increasing, gradually moving towards electrification and automation. To ensure the safe production of coal mine enterprises, computers are used to realize remote monitoring and management datafication, automated production management, and simple operation, ultimately achieving safe production and increasing coal output. The new SCADA data acquisition system adopts industrial Ethernet network switches, intelligent I/O modules, industrial controllers, and various coal mine safety sensors to form a remote coal mine monitoring system, realizing networked real-time data acquisition and storage, motion control, and early prediction. 2 Introduction to the Data Acquisition System for Large Equipment in Coal Mines 2.1 Introduction to the Overall System Structure The industrial ring Ethernet monitoring system is an easily expandable and open monitoring system. It is currently the world's most advanced open solution for process automation systems and a new generation of open SCADA (easily expandable and open monitoring system) for factory automation. The network design consists of a management computer at the monitoring center, a digital server, a video server, a ring network switch, and various mining instruments. The backbone network of the system adopts 100M industrial Ethernet technology to ensure high-speed transmission and exchange of monitoring information and to ensure the real-time performance of the system. The backbone network is designed with redundancy, and the equipment has error correction capabilities, flexibility, and scalability, ensuring high reliability and supporting multiple network protocols. The backbone network is connected using Fiber Distributed Data Interface (FDDI). The topology of the entire ring network is shown in Figure (1). The entire mining area is vast and widely distributed, consisting of a central monitoring station and multiple monitoring substations, specifically including a remote network monitoring central station, a machinery and transportation substation, an auxiliary vertical shaft substation, an auxiliary inclined shaft substation, an air compressor substation, multiple fan substations, a central pump station substation, a main inclined shaft conveyor substation, a main haulage roadway conveyor substation, and a sales and transportation station substation. The system requires the collection of 441 analog quantities, 209 switch quantities, and 4 pulse quantities, including 46 backup protection devices and instruments with RS485 communication ports. The system establishes subsystems/substations in each area, with each substation acting as both a lower-level and upper-level machine. Subsystems can also independently process commands from their own system, employing distributed control to disperse risks. Localized failures will not affect the normal operation of the entire system, thus ensuring its continued operation. [align=center] Figure (1) Topology of Remote Ring Network Monitoring System[/align] 2.2 Subsystem Structure: Since the data acquisition principles of the large equipment in each subsystem are similar, the structure and composition of the monitoring substation are explained below using the auxiliary shaft winch room as an example. The monitoring substation subsystem is shown in the figure below. The system is connected to the backbone network through a real-time ring industrial Ethernet switch. The main field equipment includes an Ethernet I/O concentrator, a 16-channel analog input module, an 8-channel high-speed counter module, a 16-channel digital input module, a power supply module, and a monitoring computer. The software used in each subsystem is KingSCADA 6.5. This configuration software can realize dynamic data, screen monitoring, historical data analysis, historical trend curve generation, real-time alarm function, rich content, vivid interface, and maintain good human-machine dialogue. The auxiliary shaft system diagram is shown in Figure (2): [align=center] Figure (2) Auxiliary shaft winch house system structure[/align] This subsystem can realize multiple functions: network the hoisting winch house with the main monitoring computer, and the monitoring room can check and view the hoisting winch's operating status in real time through the network; it can automatically monitor and record various parameters of the hoisting winch in real time in the form of a screen, and automatically generate tables or historical curves; the operating status of the operating equipment and backup protection, audible and visual alarms, storage and query of various data, and also provide online help and other functions to solve difficult problems encountered in actual operation. 3 Functional configuration and communication of each part 3.1 Functional configuration of each part 1) The central control is mainly the center for displaying and controlling the operating equipment status of the entire coal mine system. It is the control center of the network management SCADA system and the place with the highest data security requirements in the entire system. The system configuration is to choose redundant configuration to realize redundancy of Server, network, communication and various functional links. The hardware of the central control room consists of SCADA real-time data server, configuration monitoring software, historical data server, Ethernet switch, engineer operation station, operator workstation and its corresponding firewall, router and other network equipment. 2) Each area mainly consists of configuration software, monitoring software, Ethernet switches, hubs, intelligent I/O modules, various sensors, and PCs, etc., to complete local data acquisition and intelligent control, and directly display the operating status of each device through the PC. Simultaneously, data can be directly transmitted to the host computer for display on a large screen, while data is stored in a digital server and updated in real time. The entire system adopts a modular design, with memory and communication interfaces providing users with expandable space, allowing for the addition of I/O modules at any time. Redundancy is also incorporated into the design of each module. The system uses the SEATRAK ST-GT series controller, featuring a 32-bit PowerPC CPU with processor performance similar to high-end Pentium processors, resulting in powerful processing capabilities. The system is certified to CSA C22.2 CLASS 1, ZONE2, and EN50021 standards for hazardous areas, meeting the requirements for use in coal mine areas. 3) The main functions implemented at each substation include data acquisition, automatic control, parameter storage, real-time communication, and fault alarms. The system utilizes a real-time ring network Ethernet switch manufactured by SIXNET Corporation in the United States. This represents a breakthrough in Ethernet technology, providing fault tolerance and correction capabilities, enabling the construction of a stable and reliable network, and offering ease of use. Users can maintain the real-time ring network Ethernet switch much like they would maintain instrumentation equipment in a workshop. 3.2 System Communication 3.2.1 Industrial ring Ethernet is used in the data acquisition system to achieve remote communication. The system employs advanced technologies such as computer networks and fiber optic communication to construct a 100Mbps high-speed underground internet connection that meets explosion-proof requirements in coal mines with harsh environments, dispersed personnel and equipment, and special installation requirements. The core of the system is to establish an industrial digital network system with open protocols in the mine, transmitting equipment monitoring data, voice information, and video image information, providing a reliable high-speed information platform for the comprehensive automation of the coal mine. The entire ring network extensively uses temperature sensors, pressure sensors, wind pressure sensors, current and electricity sensors, and hydrostatic pressure sensors. Signals are converted into digital quantities and transmitted to the host computer for large-screen display and data storage. 3.2.2 The video system, voice system, and equipment operation status acquisition system are integrated into one system. This data acquisition system involves both image and voice acquisition, further ensuring coal mine safety. All selected instruments adhere to the Modbus communication protocol, enabling high-speed transmission and possessing strong ring self-healing capabilities. The video system utilizes video converters, network image processors, VGA matrix switchers, and various explosion-proof cameras, employing mature video surveillance technology for coal mine safety monitoring; the same applies to the voice system. The ring-shaped remote monitoring network offers significant scalability and redundancy; therefore, the two additional systems are directly connected to the industrial Ethernet ring network. Simultaneously, the system backbone employs 100M industrial Ethernet technology to ensure high-speed transmission and exchange of monitoring data, video images, and voice information, guaranteeing system real-time performance. The system control center is the core of the entire system. Monitoring data, video images, and voice information from all monitoring substations are transmitted to the center via high-speed industrial ring-shaped fiber optic Ethernet. The monitoring center displays dynamic graphics, real-time data, data reports, trend curves, early warning information, voice information, and video images, achieving real-time 24-hour online monitoring of the safe operating status of all fixed equipment in the mine and providing early warnings of potential accidents. Figure (3) is the system diagram of the control center, which mainly includes: monitoring station, data server, video server, large screen video wall system, etc. [align=center] Figure (3) Control Center System Diagram[/align] 4 Software Design In some areas, the lower-level machine software uses the Kingview 6.51 development software of Beijing Yacon Technology Development Co., Ltd., and in some areas, the 256-point Kingview development software is used. The upper-level machine and other management layers with access permissions use the Kingview 6.51 running software. It is currently one of the leading data acquisition and monitoring software in China, with powerful functions, capable of independent interface development, and supporting web connection. As it is a networked management system, in order to prevent virus intrusion, it is necessary to install antivirus software and strengthen personnel management. The antivirus software used is Kingsoft Antivirus, and it is guaranteed to be upgraded regularly; strict relevant systems must be formulated for personnel management and personnel training must be strengthened. The main functions of the monitoring software are: (1) Data acquisition: Real-time local centralized monitoring of the operating parameters, power parameters, working status, protection status, and audible and visual alarm information of each main fan, air compressor, main drainage pump, main shaft belt conveyor, auxiliary vertical shaft, inclined shaft winch, main roadway and transportation station belt conveyor; and can display its operating status diagram and values in real time. The system is developed through industrial configuration software to realize real-time data curves and historical data curves, which are displayed on the large screen. (2) Alarm: KingSCADA provides alarm function, which can be a buzzer alarm or an audible and visual alarm. When the collected data exceeds the set values of each segment, an alarm is given, and the operator or decision-maker should pay attention to take measures. At the same time, the authorized staff can directly modify the parameters online. (3) Remote control: The most common control is in the vertical shaft and inclined shaft, mainly for motor control and bearing clearance control. Bearing clearance adjustment requires control of various hydraulic valves, flow meters, etc. In the pump room, the main control is motor start and stop control. When the data collected by the hydrostatic pressure sensor is too large to a certain value, another or two water pumps are started. If the temperature of the main roadway belt is too high or the data collected by the smoke sensor exceeds the limit, the sprinkler device is automatically started. (4) Historical data recording and query: Data can be collected in real time in the host computer and written into the database. The database is also updated and stored in real time, which is convenient for querying and further data analysis. (5) Operation history record: KingSCADA can automatically record each operation record. In actual management, only authorized personnel or chief engineers can operate it, which can further ensure the safety and stable operation of the system. (6) Online query of various reports and printing: KingSCADA monitoring software can directly access the operating status of each area of equipment through IP. At the same time, reports can be printed according to customer needs. (7) Provide a complete online help system: When a fault occurs in the system, online help can be provided to directly solve the difficult problems encountered in operation. For complex problems, the voice system, video system and online personnel can be combined to solve the problem quickly. (8) Convenient and quick equipment management function: The operating status of each device can be fully observed in the central control room, including detailed information of each device, which facilitates the management of the device. 5 Conclusion The innovation of the author of this paper: The design scheme of the coal mine data acquisition system based on industrial Ethernet ring network is presented. The new industrial Ethernet ring network product (widely used in the US military) is used to realize the video system, voice system and data acquisition system sharing a single industrial Ethernet ring network with fiber optic backbone. Not only does the design meet the user's needs, but the product also ensures the stability of the system. The whole system scheme has been recognized by the user and industry experts. The new generation SCADA system proposed in this paper is also the early warning system of the coal mine, which further protects the life safety of coal mine personnel and equipment safety, thereby avoiding or reducing more safety production accidents and direct economic losses. References: [1] Beijing Yacon Company. KingSCADA 6.5 User Manual. Beijing Yacon Technology Development Co., Ltd. December 2003 [2] Yang Xianhui. Industrial Data Communication and Control Network. Tsinghua University Press. January 1, 2003 [3] Liu Peng, Xue Peiding. Design of SCADA System for Urban Gas Pipeline Network. Microcomputer Information. Vol. 21, No. 4, 2005, p78-79 [4] Lei Huang. Distributed SCADA Monitoring and Data Acquisition System for Mines Based on CAN Bus. Taiyuan University of Technology. November 2002 [5] Wang Yifeng, Wen Xidong. Design of Data Acquisition Module Based on CAN Bus. Microcomputer Information. Vol. 21, No. 11-2, 2005, p58-60 Design of Remote Data Acquisition System Based on Industrial Ethernet