National Vocational College Skills Competition - GZ037 Industrial Internet Integrated Application Competition - Question 3~4

Table of contents

National Vocational College Skills Competition - GZ037 Industrial Internet Integrated Application Competition - Question 3

Instructions for the first part of the competition

The second part of the competition task

National Vocational College Skills Competition - GZ037 Industrial Internet Integrated Application Competition - Question 4

        Instructions for the first part of the competition

The second part of the competition task

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National Vocational College Skills Competition - GZ037 Industrial Internet Integrated Application Competition - Question 3

Instructions for the first part of the competition

• contest requirements

1. Correct use of tools and operation safety regulations;

2. If there is any objection during the competition, it can be reported to the referee, and the order of the field must not be disturbed;

3. Obey the field discipline, respect the referee, and obey the arrangement.

• Professionalism and Safety Awareness

1. All operations to complete the competition tasks are in compliance with the safety operation specifications, and pay attention to the safety of electricity use.

2. Obey the discipline of the arena, respect the staff of the arena; cherish the equipment and equipment of the arena.

• Point deduction

1. During the competition, if the equipment is destructively damaged or caused an accident due to improper operation, it will depend on the circumstances.

10 to 20 points, if the situation is serious, the qualification will be disqualified.

2. Behaviors that do not conform to professional standards, such as disheveled clothing, polluting the arena environment, disturbing the order of the arena, and interfering with the work of referees, will be deducted from the corresponding professionalism in Module 3. If the circumstances are serious, they will be disqualified from the competition.

• Notice to Players

1. If there are problems such as missing pages or unclear handwriting in the task book, please notify the referee in time and replace it;

After the competition, all paper materials and USB flash drives provided by the competition shall not be taken away from the competition venue.

2. Please operate in strict accordance with the requirements of the mission statement and process specifications for the installation and configuration of the equipment.

3. Participating teams should complete the content required by the mission statement within the specified time. The documents and materials formed during the mission realization process must be stored in the designated location of the U disk, and at the same time copy a copy of the "submitted materials" to the "D disk" root of the server. Under the directory, files that are not stored in the specified location will not be scored.

4. During the competition, if the player determines that the device or device is faulty, he can ask the referee to replace it; if the device or device is determined to be intact, it is a misjudgment, and the time for the device or device to be recognized will be included in the competition time; if the device or device is determined to be If there is a fault, the equipment will be replaced on the spot. For the time loss caused during this process (from the start of equipment detection to the completion of the replacement), after the end of the game time, the team will be compensated for the same amount of time delay.

5. Devices will not be replaced if they are damaged due to human error during the competition.

6. After the referee team announces the end of the competition, the contestants should immediately stop any use of the competition equipment and computers.

what to do.

The second part of the competition task

• mission requirements

In response to the national energy dual control and the overall guidelines of "carbon peaking and carbon neutrality", industrial enterprises are very urgent to build an energy management system with real value for energy saving and emission reduction. As a big manufacturing country, my country has many high-level For energy-consuming industrial enterprises, the construction of energy management system can realize the orderly, effective and powerful development of energy utilization and management.

As large-scale enterprises enter the high-quality development stage of industrial upgrading, cost reduction and efficiency enhancement, the contradictions with new requirements such as "dual control" of energy consumption, environmental pollution, safe production, and technological upgrading have become increasingly prominent. A certain enterprise is facing challenges in the field of energy management The challenges and problems to be solved are:

1. The level of energy utilization is not high, and energy waste is common

With the industrial upgrading and rapid development of enterprises in recent years, energy has played a huge auxiliary supporting role, but the overall energy consumption per unit of products of enterprises has shown a slight upward trend, and there are various degrees of waste in various energy processes. In the past year, it has been found that enterprises There were at least 21 (long) shutdowns of equipment idling, and 174 other energy wastes were discovered through self-examination.

1. There are hidden dangers in energy security, and energy quality affects production and operation

The high-quality supply of energy is the guarantee for the stable production and product quality of the enterprise. Among them, the power quality, pressure, temperature, etc. are all key indicators of energy quality. In the past year, the enterprise has caused more than 121 equipment shutdowns or failures due to abnormal energy quality.

1. The energy system has many specialties and management is scattered, making it difficult to centralize scheduling

The production dispatching center of the enterprise is responsible for the production and energy dispatching of the entire enterprise. Before this project went online, only part of the energy automation system was connected to the production dispatching center, and leaders at all levels could not remotely understand the on-site energy status. Feedback from level to level, and then the Public Utilities Department conducts on-site inspections, resulting in a lot of time wasted in the process, and even information transmission errors may occur.

In order to carry out an effective smart energy management plan and adopt the industrial Internet integrated application architecture to build a smart energy system in the industrial production link, the following tasks need to be completed:

1. Interconnect and integrate the equipment in the existing industrial production links.
2. Collect data from energy equipment in industrial production.
3. Identify and analyze industrial production equipment and products.
4. The collected energy data is preprocessed and displayed in multiple dimensions on the edge server.
5. Configure the industrial Internet platform to build smart energy management in industrial production.

• task environment

Hardware resources: computers, industrial Internet integrated application workstations, industrial Internet platforms, toolboxes, consumables, etc.

Software resources: see the "competition data" folder in the U disk.

• task implementation

Module 1 Industrial Internet equipment installation and commissioning (35 points)

Task 1-1 Industrial Internet equipment installation

There are a variety of production sensing equipment, control equipment and network equipment on the industrial production training platform. It is required to complete the network interconnection integration of industrial Internet network equipment to ensure the normal operation of the industrial Internet network equipment environment after the network interconnection integration.

Task requirements:

1. The logic of the industrial production network topology diagram planned by the contestants is clear.
2. The IP industrial production equipment address logic planned by the contestants is correct.
3. Contestants correctly install network equipment such as firewalls and industrial switches.

After completing the above tasks, please do the following steps:

1. Use drawing design software and other tools to draw the network topology diagram of industrial production equipment, and draw the network topology diagram of industrial production equipment, industrial energy equipment, industrial network equipment, edge servers, and player PCs.
2. Use Excel to write IP industrial production equipment address planning for industrial equipment.
3. Install firewalls, industrial switches and other network equipment: use direct network cables to interconnect the industrial production main server system network; use network cables to connect the corresponding interfaces to interconnect the switch network.

Task 1-2 Industrial Internet equipment debugging

Task requirements:

1. Contestants correctly configure the IP addresses of network terminal devices such as industrial production controllers.
2. Competitors can connect to the network according to the planned and designed industrial production equipment topology through cables, and the connection is correct.

After completing the above tasks, please do the following steps:

1. Configure network terminal equipment such as industrial production controllers and IP addresses: use a direct network cable to connect the PLC controller; use a direct connection network to connect the gateway; use a direct network cable to connect the player’s PC; power on the system: training platform Power on, power on the PC, and power on the edge server.
2. Through communication cables, network interconnection and integration are carried out in accordance with the planning and design of industrial production equipment topology diagrams: network debugging is carried out, and PCs communicate with training hosts and edge servers.

Module 2 Industrial Internet Platform Development and Application (60 points)

Task 2-1 Data Acquisition System and Application

Task requirements:

1. Contestants need to correctly configure the gateway industrial Ethernet communication protocol parameters.
2. Contestants need to collect industrial equipment data through the MQTT application transmission protocol for data collection.

After completing the above tasks, please do the following steps:

1. Conduct industrial production configuration gateway ModbusTCP industrial Ethernet communication protocol parameters.
2. Configure the industrial production gateway MQTT application transport protocol to publish and subscribe topics.
3. MQTT publish and subscribe tests are required.
4. Conduct data acquisition and debugging tests on industrial production equipment and energy collection equipment.

Task 2-2 Integrated Application of Identification Analysis System

Task requirements:

1. Contestants must correctly register industrial production equipment and products into the platform.
2. Contestants will use the identification data to collect to the platform, and trace equipment and products.

After completing the above tasks, please do the following steps:

1. Coding and registration of industrial production equipment and product identification.
2. The product is identified and encoded according to the identification and encoding rules.
3. Integrate the identification analysis equipment with the product identification data acquisition equipment and platform.
4. Collect industrial equipment and product identification data to the platform for traceability.

Task 2-3 Edge Computing and Data Visualization Applications 

Task requirements:

1. Contestants can correctly build and start the Pycharm environment, and run Python scripts correctly in the Pycharm environment.
2. The contestants correctly import the collected industrial energy data and display the basic information of the data.
3. Contestants can perform correct data processing on industrial energy data: remove null values, remove outliers, etc.
4. Contestants can make energy trend charts within a month.
5. Competitors can generate comparison charts of energy data in daily units.

After completing the above tasks, please do the following steps:

1. Build the Python IDE development environment.
2. Import of industrial production data at the edge of the Industrial Internet.
3. Industrial production data processing at the edge of the Industrial Internet: data exploration, data preprocessing.
4. Data visualization environment construction.
5. Use a Python script to draw a histogram to show the distribution of energy data in industrial production.
6. Use a Python script to draw a grouped histogram to show the comparison of energy data in industrial production.

Task 2-4 Industrial Internet Application Platform Service Development

Task requirements:

1. Contestants need to correctly configure the connection between the industrial Internet platform and the edge device.
2. Contestants need to configure cloud monitoring applications to form industrial Internet energy monitoring.

After completing the above tasks, please do the following steps:

1. Connect to the industrial Internet platform, and configure the connection between the edge device and the industrial Internet platform.
2. Configure the real-time computing center of the industrial Internet platform: automatic conversion of equipment data and measurement point data, real-time processing of time series data, and custom data forwarding rules.
3. Industrial Internet platform basic application service configuration: configured threshold alarm rules and monitoring, process 2D configuration.
4. Display the configured basic application services: real-time data detection and historical data viewing.

National Vocational College Skills Competition - GZ037 Industrial Internet Integrated Application Competition - Question 4

Instructions for the first part of the competition

• contest requirements

1. Correct use of tools and operation safety regulations;

2. If there is any objection during the competition, it can be reported to the referee, and the order of the field must not be disturbed;

3. Obey the field discipline, respect the referee, and obey the arrangement.

• Professionalism and Safety Awareness

1. All operations to complete the competition tasks are in compliance with the safety operation specifications, and pay attention to the safety of electricity use.

2. Obey the discipline of the arena, respect the staff of the arena; cherish the equipment and equipment of the arena.

• Point deduction

1. During the competition, if the equipment is destructively damaged or caused an accident due to improper operation, it will depend on the circumstances.

10 to 20 points, if the situation is serious, the qualification will be disqualified.

2. Behaviors that do not conform to professional standards, such as disheveled clothing, polluting the arena environment, disturbing the order of the arena, and interfering with the work of referees, will be deducted from the corresponding professionalism in Module 3. If the circumstances are serious, they will be disqualified from the competition.

• Notice to Players

1. If there are problems such as missing pages or unclear handwriting in the task book, please notify the referee in time and replace it;

After the competition, all paper materials and USB flash drives provided by the competition shall not be taken away from the competition venue.

2. Please operate in strict accordance with the requirements of the mission statement and process specifications for the installation and configuration of the equipment.

3. Participating teams should complete the content required by the mission statement within the specified time. The documents and materials formed during the mission realization process must be stored in the designated location of the U disk, and at the same time copy a copy of the "submitted materials" to the "D disk" root of the server. Under the directory, files that are not stored in the specified location will not be scored.

4. During the competition, if the player determines that the device or device is faulty, he can ask the referee to replace it; if the device or device is determined to be intact, it is a misjudgment, and the time for the device or device to be recognized will be included in the competition time; if the device or device is determined to be If there is a fault, the equipment will be replaced on the spot. For the time loss caused during this process (from the start of equipment detection to the completion of the replacement), after the end of the game time, the team will be compensated for the same amount of time delay.

5. Devices will not be replaced if they are damaged due to human error during the competition.

6. After the referee team announces the end of the competition, the contestants should immediately stop any use of the competition equipment and computers.

what to do.

The second part of the competition task

• mission requirements

With the rapid development of the new generation of information technology, industrial Internet technology is promoting the upgrading and transformation of traditional manufacturing to digital and intelligent direction. The labeling and networking of industrial equipment is of great significance in industrial production. It can not only optimize the production process and management methods, improve production efficiency, but also promote the integration of industrialization and informationization, realize the intelligentization of industrial production, and contribute to the construction of modern Intelligent industrial system has positive significance.

In order to realize the whole process of automatic packaging production of materials, a company needs to upgrade the network structure, collect production line signals, develop a new identification system to manage each link, use edge computing technology to improve the real-time performance of information processing, and design an industrial Internet platform Application software realizes data visualization and service applications.

• task environment

Hardware resources: computers, industrial Internet integrated application workstations, industrial Internet platforms, toolboxes, consumables, etc.

Software resources: see the "competition data" folder in the U disk.

• task implementation

Module 1 Industrial Internet equipment installation and commissioning (35 points)

Task 1-1 Industrial Internet equipment installation 

1. mission details

The installation of the industrial network technology comprehensive application platform equipment has been completed, but the industrial Internet identification analysis equipment (RFID reader) of the intelligent storage and intelligent detection units has not yet been installed and debugged. Now you need to complete the following tasks:

(1) According to the network wiring diagram, complete the installation, electrical and network wiring connection of the industrial Internet identification analysis equipment (RFID reader) of the intelligent storage unit.

( 2 ) According to the network wiring diagram, complete the installation, electrical and network wiring connection of the intelligent detection unit industrial interconnection data acquisition equipment (intelligent IO\valve island).

2. Network Wiring Diagram

 

 

Task 1-2 Industrial Internet equipment debugging

1. mission details

( 1 ) According to the equipment IP address allocation table, use relevant software and configuration files to complete the network configuration of the intelligent storage unit, intelligent detection unit PLC and RFID reader, and realize the reading of material label data; the software has been installed on the equipment programming computer Above; RFID configuration files and RFID data manuals are placed in the folder directory of the competition folder on the D disk of the computer. Store the RFID reader configuration content, PLC communication configuration, and screenshots of PLC and RFID reader test results in the specified path ("D:\skills competition\examination room number + station number\identification analysis equipment configuration"), with "1 -1-2-* "Industrial Internet Identification Analysis Device Configuration" named as the scoring result.

( 2 ) Complete the network configuration, parameter configuration and System optimization and debugging. The software is already installed on the device programming computer.

2 . Device IP address allocation table

Table 1-1 IP address allocation table for intelligent storage unit equipment

name	IP address	Remark
PLC	192.168.1.21
Smart valve island\smart IO	192.168.1.22
RFID read/write head	192.168.1.24	Port number: 9000

Table 1-2 IP address allocation table for intelligent detection unit equipment

name	IP address	Remark
PLC	192.168.1.31
Smart valve island\smart IO	192.168.1.32
RFID read/write head	192.168.1.34	Port number: 9000
visual camera	192.168.1.35

Module 2 Industrial Internet Platform Development and Application (60 points )

Task 2 -1 Data Acquisition System and Application

1. Task description

The industrial network technology comprehensive application platform equipment is docked with the industrial Internet platform to realize data monitoring, control equipment and other operations of the industrial Internet platform, and it is necessary to complete the installation and commissioning of the industrial Internet network equipment. The industrial Internet platform (hereinafter referred to as the platform) communicates with the intelligent storage unit and the intelligent detection unit through the edge all-in-one machine, and completes the object model, order issuance, data collection and equipment control. Therefore, before conducting business operations, it is necessary to first complete the industrial network configuration and establish a data path between the equipment and the industrial Internet platform.

Please complete the network configuration on the platform side and edge all-in-one machine according to the following information. See "D:\ References \Network Configuration" for the configuration file (Note: The configuration requirements include the test group number, IoT platform address and login account and password, edge all-in-one machine IP address, network configuration software access address and login user name and password , gateway acquisition configuration software access address and login user name and password).

2. PLC device IP address allocation table

Table 1- 4  PLC device IP address allocation table

name	IP address	Remark
Intelligent storage unit PLC	192.168.1.21
Intelligent detection unit PLC	192.168.1.31
Intelligent logistics unit PLC	192.168.1.51

3. IP address planning of the edge all-in-one machine and three devices

equipment	IP address	Remark
Edge all-in-one	Network port A: 192.168.200.15 (default, fixed) Network port B: 192.168.1.200	Network port A: fixed, access the web page; network port B: communicate with the device; Network port C: communicate with the platform;
Intelligent storage unit	192.168.1.21
Intelligent detection unit	192.168.1.31

4. Industrial Internet component information

HOST	www.ChinaSkills2013.com
PORT	1883
username	admin
password	ChinaSkills2013!

Task 2 -2 Integrated application of identification analysis system

The industrial network technology comprehensive application platform equipment is docked with the industrial Internet platform to realize the data monitoring and control equipment operations of the industrial Internet platform, and it is necessary to complete the installation and debugging control of the industrial Internet network equipment. Through the configuration of the platform, the data of the intelligent storage unit and the intelligent detection unit are collected, and the data of the intelligent detection unit are preprocessed: pass rate, appearance pass rate, storage pass rate, filling quantity pass rate configuration, and the data of the two units will be collected data visualization.

Preprocessed data calculation formula:

Qualified rate = number of qualified products \ total number of tests;

Appearance qualified rate = Appearance qualified product number \ total number of inspections;

Storage pass rate = number of qualified products in storage \ total number of inspections;

Filling Quantity Qualification Rate = Filling Quantity Qualified Products \ Total Inspection.

Now you need to complete the following tasks:

(1) Take a screenshot of the model list , save it as " 2-1-1-1 model.jpg ", and save the batch export model property file as " 2-1-1-2 Smart Warehouse Model Properties.zip" and " 2-1- 1-3 Intelligent detection unit model attributes.zip", the save path is "D:\skills competition\examination room number+work station number\industrial data on the cloud".

(2) The names of the created equipment are "intelligent storage equipment" + "examination group number" and "intelligent detection unit equipment" + "examination group number". The screenshot saves the equipment list " 2-1-2 -1 equipment list.jpg", and the save path is "D:\skills competition\exam room number+work station number\industrial data on the cloud".

(3) Create a southbound device named "industrial production line PLC" + "examination group number", and complete the communication configuration, save the screenshot as "2-1- 3- 1 PLC device.jpg "  ; bind the production line From the unit to the PLC device, the screenshot is saved as " 2-1- 3- 2 PLC sub  -device list.  Material equipment point list.jpg" and " 2-1-3-4 intelligent logistics  equipment point list.jpg", the save path is "D:\skills competition\examination room number+work station number\industrial data on the cloud" .

(4) Check the equipment running status in the "Equipment Monitoring" of "Asset Monitoring" on the Internet platform. Take screenshots to save the running status pages of the two devices, and save them as " 2-1-4-1  Smart Storage Device Running Status.jpg" and " 2-1-4-2 Smart  Detection Unit Device Running Status.jpg", save the path It is "D:\skills competition\examination room number+work station number\industrial data on the cloud".

(5) The visualization page drawing of intelligent storage and intelligent detection unit is completed, and the screenshots are saved as " 2-1-5-1  Intelligent storage visualization drawing.jpg", " 2-1-5-2  Intelligent detection unit visualization scene.jpg" , the save path is "D:\skills competition\exam room number+work station number\data monitoring".

(6) In the visualization page of the intelligent storage and intelligent detection unit, the screenshot of script writing when the "Run" graphic element is bound to the point is saved as "2-1-6-1 Smart Storage Visualization Script.jpg", and the save  path is "D:\ Skills competition\examination room number+work station number\data monitoring".

(7) Take the screenshot of the binding device result of the visual interface of the binding point of the intelligent storage and intelligent detection unit, and save it as " 2-1-7-1 Intelligent storage visualization device binding.jpg", " 2-1-7-2  Intelligent detection unit visualization device binding.jpg", the save path is "D:\skills competition\examination room number+work station number\data monitoring".

Task 2 - 3 Edge Computing and Data Visualization Applications

The industrial network technology comprehensive application platform equipment is docked with the industrial Internet platform to realize data monitoring, control equipment and other operations of the industrial Internet platform, and it is necessary to complete the functional configuration and integrated application debugging of the industrial Internet platform.

The platform enters the production data, starts all unit production lines with one click, sends the production data to the production line, detects the production unit and uploads the equipment information and production information to the platform, and the platform monitors and updates the production order information until the production is completed.

Now you need to complete the following tasks:

(1) According to the PLC acquisition table and operation process, on the basis of the original program, complete the PLC program editing of the remote control equipment operation of intelligent storage, intelligent detection unit, and intelligent logistics unit, realize the visual interface of the production line through the industrial Internet platform, and control the whole equipment operation.

(2) According to the PLC acquisition table and operation process, on the basis of the original program, complete the editing of the PLC program for the remote order issuance of intelligent storage, intelligent detection unit, and intelligent logistics unit, and realize the operation visual interface through the industrial Internet platform, and issue orders to the equipment .

(3) According to the operation process and unit I\O module allocation table, complete the PLC program programming of the quality inspection of the intelligent detection unit and the classification and storage of materials in the intelligent logistics unit.

( 4 ) Now the factory has received an order for 5 bottles of pharmaceutical production, the type of drug is calcium tablets, and the number of filling granules in a single bottle is 4 capsules. Due to the limited production time that the daily production line can devote to this order, the order needs to be completed in three batches. 6 0% on the first day , 2 0% on the second batch , the rest of the third batch is completed, and the first batch is now being produced. The screenshot work order is saved as " 2-2-4-1 Industrial Production Line Production Order.jpg", save the path It is built for "D:\Skills Competition\Examination Room No.+Workplace No.\Industrial Production Line Application".

(5) Configure the production monitoring and quality monitoring pages of the production line, save the screenshots as " 2-2 - 5-1 Industrial Production Line Monitoring.jpg", " 2-2 - 5-2 Industrial Production Line Quality Monitoring.jpg" save path It is built for "D:\Skills Competition\Examination Room No.+Workplace No.\Industrial Production Line Application".

(6) View the deployment application on the edge all-in-one machine, save the screenshot as " 2-2 - 6-1 Industrial Production Line Application Deployment. Application Build".

(7) When the production is completed, take a screenshot to save the production schedule list, save it as " 2-2 - 7-1 Production Monitoring_Production Completion.jpg", and save the path as "D:\Skills Competition\Examination Room No.+Workplace No.\ Industrial production line application construction".

(8) After the production is completed, screenshots of quality monitoring and production line monitoring are saved as " 2-2 - 8-1 Production Monitoring_Quality Monitoring.jpg", " 2-2 - 9-1  Production Monitoring_Production Line Monitoring.jpg ", the save path is "D:\Skills Competition\Examination Room No.+Workplace No.\Industrial Production Line Application Construction".

Task 2 - 4 Industrial Internet Application Platform Service Development

The equipment of the comprehensive application platform of industrial network technology has just been installed, and there are faults. Now it is necessary to complete the equipment fault finding and troubleshooting, and debug the equipment to make it run smoothly.

The intelligent storage unit and the intelligent detection unit have the risk of failure during use. Alarms are configured on the platform based on possible failures. When a unit fails, an alarm will be triggered to notify the user of the failure. The user performs troubleshooting according to the triggered alarm information, and after the troubleshooting, the device is restarted, and no alarm information is triggered again.

(1) According to the relevant drawings and materials of the equipment, complete the fault finding and troubleshooting; and carefully record the fault point and fault phenomenon on the troubleshooting table of the "Troubleshooting Table", and write down the cause of the fault and the solution. If the number of lines on the troubleshooting table is insufficient, You can add your own form lines to fill in.

(2) Possible failures of the unit:

• When the intelligent storage material is insufficient, it will give an alarm prompt: the level is six, and the type is abnormal output;
• When the qualified rate of production is less than 95%, the alarm indicates that the quality of the production line is abnormal: the level is level 4, and the type is abnormal output
• After the production order is sent to the production line, if the order is not completed, any device stops production and gives an alarm prompt: level 8, type is other, and a fault occurs;
• Screenshot of the rule list, save it as " 2-3-2-1  production monitoring_rule list.jpg", and save it in the path "D:\skills competition\exam room number+work station number\alarm handling "

（3）在一键启动下发生产订单时，设备存在故障，会触发告警，触发告警截图，保存为2-3-3-1 生产监控_故障告警.jpg”，保存路径“D:\技能竞赛\考场号+工位号\告警处理”

（4）修复处理完告警详情截图，保存为“2-3-4-1生产监控_告警处理.jpg”，保存路径“D:\技能竞赛\考场号+工位号\告警处理”