How to solve the problem of meter reading in petrochemical workshops without communication interfaces? This intranet visual solution provides the answer

As a professional provider of IoT data acquisition solutions and an expert in industrial IoT data acquisition, the editor of Shanghai Data Acquisition IOT Technology Co., Ltd， (daq-iot) hereby presents the following introduction, and sincerely welcomes discussions and exchanges. Supported Communication Interfaces: CAN, RS485, Mbus, 4–20mA, Profibus, CC-Link, HART, digital I/O, etc. Industrial Protocols: Modbus RTU/TCP, HJ212, IEC104, DLT645, DLMS, IEC61850, MQTT, etc. Mail:export@daq-iot.com

In high-precision production scenarios such as petrochemicals,Mechanical pointer instrumentDue to its strong stability, it is widely used, but it has always been a pain point in the industry due to the lack of external communication interfaces, complex on-site environments, low efficiency of manual meter reading, and lagging data.Sinopec Shanghai Petrochemical Co., LtdThe 1500 ton carbon fiber spinning machine production line is facing such challenges.

1、 Core pain point of the project: Why is traditional meter reading difficult to implement?

This project is implemented onSinopec Shanghai Petrochemical 1500 ton carbon fiber plant spinning machineLines 1-4 are equipped with a large number of mechanical pressure gauges in the workshop. This type of instrument has no data output interface and cannot be directly connected to automation systems; There are corrosive gases present on site, and conventional equipment is prone to damage, making construction wiring difficult and posing high safety risks; Manual meter reading cannot achieve Real-time monitoring, and the data is difficult to support timely analysis of production line operation.

To achieve the collection and effective monitoring of production line data Real-time, the project collaboratesChangjiang Institute, CustomizedInternal network visual recognition wireless meter reading solutionUsing technological means to break through the bottleneck of traditional meter reading.

2、 Technical Path: Visual+Wireless+Internal Network, How to Achieve Accurate Meter Reading?

Regarding the pointer table structure and corrosion environment, the project adoptsCamera photography+wired transmission+visual recognitionThe technical route involves capturing dial images through cameras, intelligently recognizing pointer readings, and completing data reading, storage, and analysis. A single camera can cover 1-5 instruments, suitable for on-site intensive installation needs.

Hardware SelectionSC-GP-CAMpoe Timer Camera(POE powered version)The power supply and signal share the same network cable, greatly simplifying construction and reducing wiring hazards. Tailored protective casing for on-site corrosive environment to ensure stable operation of equipment.

The system runs entirely within the internal network environment, with data not leaving the factory area, balancing security and stability.

3、 Key technical indicators: How reliable is the solution?

This plan strictly benchmarks industrial grade requirements, and the core indicators meet the rigorous standards of petrochemical scenarios:

1. Accurate recognition: When the dial is clean and unobstructed, the recognition accuracy is ≥ 99.5%, and the image is clear and distinguishable with scales and numbers;
   

1. Efficient collection: Meter reading frequency is as fast as 1 minute per time, supporting custom adjustment;
2. Stable operation: The system runs continuously and stably for ≥ 60 days, with a software failure shutdown rate of<1% and a fault handling time of<24 hours;
3. Persistent storage: Data and images are stored for at least 6 months and support traceability queries;
4. Environmental adaptation: Protection levelIP65The working temperature is -10 ℃~50 ℃, suitable for complex workshop environments.

4、 On site implementation: How to overcome corrosion and interference to ensure effectiveness?

A total of 4 sets of cameras were deployed on site, 2 sets covering 2 instruments and 2 sets covering 3 instruments, matched with instrument layout optimization installation.

During the debugging phase, the focus is on addressing environmental interference issues: removing dial labels, avoiding fogging of protective covers, adjusting installation angles to eliminate light source reflections, cleaning the dial to ensure recognition clarity, and eliminating factors that affect recognition accuracy one by one. The equipment is equipped with customized protective devices to effectively resist corrosion and ensure long-term stable operation.

5、 Implementation results: What value does visual meter reading bring?

The project has successfully implemented a mechanical pointer meterAutomation, intranet, visualizationMeter reading. The system accurately identifies instrument values, automatically stores them in the database, and achievesThe image storage path corresponds one-to-one with the recognition resultThe data is searchable, traceable, and analyzable.

This solution does not require instrument modification or complex wiring, and is suitable for high-risk corrosion environments. It perfectly solves the problem of instruments without communication interfaces and provides a replicable technical template for intelligent meter reading and digital upgrading of production lines in the petrochemical industry.