U-oriented Industrial Safety Monitoring Module Development Research

Transcription

1 U-oriented Industrial Safety Monitoring Module Development Research 1 U-oriented Industrial Safety Monitoring Module Development Research Chia-Ping Huang ABSTRACT This paper aims to provide conventional industrial sites an intelligent U-oriented industrial safety monitoring module. This new module is a solution for management level to monitor labor daily work effectively which improving current drawbacks of high working injure rates. This research focuses on the gaps between industrial safety and new technology introducing. Regarding the technique issues, the experiment involves Zigbee network topology and data warehouse techniques applications. This ensues Zigbee network will be fully functioned. After all, Zigbee network could be well connected within enterprise information systems. The literatures show that most U-oriented projects are based on the WIFI and mobile applications. Although, the Zigbee Alliance reveals that most available applications are currently automated control and environment surveillance. It shows that there is no mature product for U-industrial safety. Therefore, it is worth to study and design a novel I.T. application within zigbee-based interface design and network implementation. After testing and evaluation, this work finds that Zibee is easy to deploy and simple to assembly a wireless net work for industrial safety, but, the accuracy of each beacons seems needs more attentions on the sides of computation skills. The proposed localization algorithm can work out the inconvenient of nodes deployment and the inaccuracy of beacon position. Department of Information Management

2 2 醒吾學報第四十四期 The designed interfaces could provide a more clearly operational environment for the further research. This project does benefit both industry and academics. The overall scenarios are designed from academics and this forces students working with company from time to time. As for industries, under the impacts of finance storming, they are happy to work with academics with the supports from NSC. The proposed project actually helps both people stepping into the U era mutually. Key words:zigbee, Intelligent systems

3 U-oriented Industrial Safety Monitoring Module Development Research 3 INTRODUCTION U-oriented industrial safety monitoring module development research adopts Zigbee as bone frame to solve the problems of people identification and industrial safety within industrial engineering and management fields. For the traditional industry people, they may introduce CAPP tool to control factory production priority and material bills issues. They use PLM system to manage blue-prints and quality control contradictions. However, there is no universal-agree I.T. tool to help front man to ensure labor working environment safety issues. This is because product and machine flows could be monitored well, but controlling people working flow and then, to prevent the relevant dangerous and hazard cases is very difficult. The literature reveals that there are 63% labor have experienced of vocational injures and 23% people had serious cases. The main causes of industrial hazard are listing as below. (1) The employer could not provide enough safety facility. (2) The management level operates old fashioned way. (3) Explosive and firs and unexpected cases. (4) The labor could not follow the SOP. (5) There are many irrelevant operation people within hazard ZONE. Based on the previous reasons, this project suggests using Zigbee tags, readers, and related WIFI network to build up an I.T. system to assist management level to understand workshop people daily works. The current WIFI and intranet infrastructure could help messages transactions and real time data presentations. This could help both employer and management level to understand how to avoid unexpected cases happened and work following SOP.

4 4 醒吾學報第四十四期 INDUSTRIAL SAFETY AND MONITORING TECHNIQUES In this session, several industrial safety and monitoring techniques, algorithm and applications are reviewed and discussed as follows. 1.Current wireless I.T. system applications The problems generating from industrial safety are mainly related to people, materials, working procedures and techniques. In recently, wireless control techniques, such as RFID and Zigbee, are pushing industrials continually introducing new I.T. systems into daily working fields. For example, in the last year, Hsing-Wu has been invited to join the MOEA RFID flag-ship project which introducing RFID tag, POS, and management information system into campus. Therefore, the students could complete their purchase through POS around the campus. There are many good applications for industries to improve their quality control, warehouse management, people identification and so on. The main characteristics of currently industrial safety and monitoring techniques are WIFI network, and wireless tag rather than cable, intranet routers and magnetic cards. There are several best practices are listed as below shown. Table 1 Industrial safety and monitoring applications lists Applications Techniques Functions 1 RFID flag-ship project MOEA/Taiwan RFID, POS, WIFI E-purchase, security control, Site management 2 Pre-casting automotive management system PDA, WIFI, RFID Materials QC Warehouse management 3 Shop-floor industrial RFID/WIFI Network People Tracking Board safety system Chimei Co. 4 Finery Factory Plan RFID/WIFI Network Material Tracking System Bechtel Co. 5 Tunnel working labor identification system RFID/WIFI Network Tunnel working labor tracking using helmet and RFID tag

5 U-oriented Industrial Safety Monitoring Module Development Research 5 Japan 6 Safe Tool AB Sweden RFID Reader Area Security Container System Safety Tank 7 Taipei water supplying construction site people identifications system Gini Tech/Taipei Electronic Board Zigbee/WiFi People identification/ Positioning and precaution 2.Wireless position algorithm The differences among WIFI, RFID, Zigbee, and Bluetooth are the accuracy of positioning algorithm. This could causes people, materials, and finished goods initially tracking well, but reporting badly. There are three main position algorithm compared as follows. (1) Hop-count based algorithm This position method could be itemized into 5 steps as below. [1][2] Reference nodes broadcasting: The first step is to enable the fixed address Zigbee nodes. The signals have been broadcasting from these fixed nodes to the neighborhood. These records will be the first data to define every nodes and beacons distance. The least figures of Hop-count: This step aims to provide relationships between reference nodes and beacons based on the law of the most short-path principle. The distance between beacons: A formulation to calculate beacons average distance could be derived from the previous data. The numerator represents the figures of reference nodes distances. The denominator means the hop-count between references. The distance between beacons and reference nodes: Using Proportion principle to calculate each distance between beacon and reference node. (2) MDS-based algorithm The Multi-Dimensional Scaling (MDS) algorithm is one of numerical analysis approaches. The basic idea is matrix representation and detailed operation processes are illustrated as follows. [3][4]

6 6 醒吾學報第四十四期 The first step is to assemble a distance square matrix. These matrix elements are recorded by the nodes and related neighborhood estimated distance. Then a distance square matrix is formed by the square of each element. The second step is called double centering. This step aims to transform beacons inner product matrix into vector quantity. The correspondent Eigen-value will identify every matrix elements inner matrix and Eigen-vector. The reverse matrix of previous elements inner matrix will provide more accuracy beacons position. This approach may be good for indoor position applications which the period of wireless scanning may more than 5-8 times per second. (3) RSSI-based algorithm (Received Signal Strength Indicator, RSSI) The RSSI-based algorithm is relied the accuracy of radio strength. There are several steps to acquire beacons position. [5][6][7] The fixed nodes receive RSSI figures from the collections between beacons and nodes. The figures of RSSI represent the distance between nodes and beacons and theses figures could tell the relative positions of each beacon. The error signals and blackout effects will affect the perceive position of the beacons. However, the spread spectrum techniques could save the drawbacks and computation algorithm may provide better solutions. This paper adopts RSSI-based algorithm to achieve the objectives of simple and fast build-up WSN. This computation method aims to provide a feasible pain-ball game tacking simulation. The details of experiment design and test are explained as follows. 3.Zigbee-based Control technique Industrial safety issues are difficult to be transformed into I.T. scenarios which employee works, in teams or individually, to cooperate with partners by hitting them. The most confusion problems for players are fairness play. This is because referee could not have any tool to show the right convict instantly and precisely. This paper aims to explain an effective algorithm could help paint-ball game company establish an easy set-up Zigbee-based sensor network which is mobile and extendable to solve problems. Regarding WSN position measurement and related improvement works, there are many

7 U-oriented Industrial Safety Monitoring Module Development Research 7 algorithms demonstrated effectively. Some approaches aim to provide precise position and others demonstrate identification purpose. Even though there is a growing awareness for Zigbee-based sensor networks applications that an integrated coordination of hardware and software is needed for current applications. Especially, the previous research efforts could not clearly establish the impact of protocols or topology management issues. This paper intends to design a more convenient and efficient localization algorithm for Zigbee wireless sensor networks for the paint-ball game. The Zigbee positioning techniques may play important role for the algorithm design. The author would like to illustrate their differences in the section II. In order to get more convenient and efficient localization algorithm for Zigbee wireless sensor networks, this paper adopts RSSI-based algorithm and fixed nodes topology to illustrate the performance of a novel mixed centroid localization algorithm within paint-ball game scenarios. There are many Zigbee positioning techniques available either based on the hardware arrangement, or relied on computation algorithm. In this study, the performance of wireless sensor network depends on the density of nodes and the quality of data signals. The position s precision could be calculated from the co ordinations of any three reference nodes. The main wireless sensor network positioning techniques are described as follows. RESEARCH METHOD AND EXPERIMENT RESULTS The experiment design is associated with a project which involved Zigbee-based industrial safety and monitoring project which supported by MOE. The general ideas are taking the advantages of Zigbee nodes and beacons to acquire shop-floor workers motions individually. This assures the original shop-floor working rules and geometry considerations. The scenarios and simulation details are described in terms of ER model, geometry design, fixed nodes and beacons position estimation algorithm as following shows. 1.Industrial site safety control scenario and simulation The U-shop-floor industrial safety and monitoring scenarios are based on the rules of working procedures which simulated the workers motion and mutual movement. The main

8 8 醒吾學報第四十四期 actors are defined as follows. Workers: Zigbee tags as beacons to response its location. Shop-floor fields: Zigbee nodes as fixed boundary address to acquire beacons signals. Daily working log: each day-log concludes number of workers, start time, teams, and working lines. The scenario is consists of three stages. The first stage is pre-work analysis. The shop-floor manager will instruct workers daily practices and safety lessons. The next one is live-recording which reference nodes and beacons are deployed by the shop-floor SOP. The final stage is reviewed and discussed which managers and foreman could have the chance to review the whole working processes with the help of this I.T. system. Figure 1 Industrial safety and monitoring scenario.

9 U-oriented Industrial Safety Monitoring Module Development Research 9 The designed I.T. system is web-based browser which is developed with visual studio 2010 and SQL server Users only need to draw and play to complete related working scenario and simulation. The shop-floor field is loaded shown in figure 2. After map loaded, users need to set-up the series number of address nodes to complete factory working area set-up. This I.T. system database consists of three datasheet: project, reader and tag. The entity-relationship model (ERM) is completed based on the previous assumptions and illustrated as follows. Each project may involve different reader and tags depending on the density of readers and number of players. For example, table 2 explains a new daily working job and Project ID is 22. The MinTagID1 and MaxTagID1 represent the shop floor workers. The MinTagID2 and MaxTagID2 represent another working people. The StartTime and EndTime means the kickoff time and finished time. Table2 Industrial safety and monitoring scenario illustration. Project ProjectID Name MinTagID1 MaxTagID1 MinTagID2 MaxTagID2 StartTime EndTime /11/27 04:59: /11/27 05:07:22 The test field is located four Zigbee nodes and their relative positions are recorded as follows. The ID numbers are 22, 23, 25, and 7. Their fixed coordination addresses are: { , }, { , }, { , }, { , }. The length of x-y axis is proportionally as one unit. Table 3 Zigbee nodes series number and coordination address.

10 10 醒吾學報第四十四期 Reader ProjectID ZigbeeID X Y Based on previous data, the system could define the fixed reader layout as shows in figure 2. Fig. 2 The fixed reader address. 2.Algorithm and data analysis This section explains the algorithm and analysis. The beacons position is derived from the RSSI readings from the fixed Zigbee nodes. The fixed nodes and their coordination are predefined whose merits from hop-count based algorithm. The position of each beacon is derived from the ration of RSSI values compared to the fixed nodes. This takes advantages from MDS-based algorithm. The proposed algorithm is illustrated as follows.

11 U-oriented Industrial Safety Monitoring Module Development Research 11 An example is undertaken from the field experiment data. From the table 4, created time on 04:59:41, there were 14 records saved into the database. The TagID 55 recorded 4 fixed nodes (22,23,25,7), and RSSI reading were 176,188,183,175. Table 4 Zigbee nodes and beacons RSSI example. Tag ID NodeID TagID CreatedDateTime RSSI /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: /11/27 04:59: The beacon, TagID 55, x and y coordination are expressed as follows. The RSSI Summary is =722 and the values of X and Y are: X= *176/ *188/ *183/ *175/722 Y= *176/ *188/ *183/ *175/722 The TagID 64, 61, and 67 are calculated and placed their position as shown in Figure 3.

12 12 醒吾學報第四十四期 Fig. 3. The position of beacons 55, 61, 64, 67. The overall movement of each beacons are shown in figure 6 which each team could select different time span to replay and review. 3.The interface and testing results In this session, the proposed I.T. system was testing and related interfaces were explained why and how the designated functions working as shown below. Table 5 The proposed I.T. system interface design and illustrations Function Figure Explanation Program Set-up The shop floor manager could set-up which assembly lines or factory needs to be recorded.

13 U-oriented Industrial Safety Monitoring Module Development Research 13 Site Map Set-up This keeps the proposed I.T. system flexible and easy to set-up. Node Position The managers could set-uo the hazard zone, working area and working SOP based the factory sites. Signal Receiving Set-up This ensures wireless data could transmit into internet and factory database flexibly.

14 14 醒吾學報第四十四期 Zigbee Parameters This assures shop-floor wireless data will be loaded into Zigbee readers. Project Records This interface provides managers to review the daily logs of shop-floor activities. People Movement This presents the live records of shop-floor workers movement. Records

15 U-oriented Industrial Safety Monitoring Module Development Research 15 CONCLUSIONS AND DISCUSSIONS Industrial safety and monitoring is an important safety management issue. The proposed approach aims to investigate a set of suitable devices and software design. A simple and effective algorithm for Zigbee based position applications is testing and assures the effectiveness. A number of interfaces are developed for the current industrial safety scenarios. After testing and evaluation, this work finds that Zibee is easy to deploy and simple to assembly a wireless net work for industrial safety, but, the accuracy of each beacons seems needs more attentions on the sides of computation skills. The proposed localization algorithm for Zigbee wireless sensor networks seems can work out the inconvenient of nodes deployment and the inaccuracy of beacon position. The designed interfaces seem provide a more clearly operational environment for the further research. In general, the experiment data and algorithm actually could help the industries to introduce advanced I.T. system to improve their industrial safety performance. These instant RSSI values and relative positions acquired seems provide the possibility of shop-floor working activities and hazard prevent functions. The next step for this project is getting beacons motion figure which may expand this algorithm further applications. ACKNOWLEDGMENT This paper is supported in part by a grant from National Science Council (NSC), Taiwan (NSC E CC3).

16 16 醒吾學報第四十四期 REFERENCES [1] Pradhan, E. Ergen, B. Akinci, Technological Assessment of Radio Frequency Identification Technology for Indoor Localization, Journal of Computing in Civil Engineering, (2009). [2] Niculescu and B. Nath, Positioning in Ad Hoc sensor networks, IEEE Network, (2004). [3] Shao-Chun Wang and Gwo-Bong Yu, A Hirarchacal MDS-based Localazataon Algorathm an Wareless, Proceedangs of the 2005 Workshop on Consumer Electronacs and Signal Processing, (2005) [4] Frank Reichenbach, Jan Blumen thal, Dirk Timmermann, Improved Precision of Coarse Grained Localization in Wireless Sensor Networks, 9th Euromicro Conference on Digital System Design, Dubrovnik, Croatia, (2006). [5] X. Luo, W. J. O Brien, C. L. Julien, Comparative evaluation of Received Signal-Strength Index (RSSI) based indoor localization techniques for construction jobsites, (2010). [6] Neal Patwari, Joshua N. Ash, Spyros Kyperountas, Alfred O. Hero III, RandolphL. Moses, and Neiyer S. Correal., Locating the Nodes :Cooperative localizationin wireless sensor networks, IEEE Signal Processing Magazine, Volume 22,Issue 4, (2005). [7] Jin Shyan Lee, An experiment on performance study of IEEE wireless networks, The 10th IEEE Conference on Emerging Technologies and Factory Automation, ( 2005).

17 U-oriented Industrial Safety Monitoring Module Development Research 17 U 化工安模組設計發展研究 黃家平 摘要 本研究主要是研提一個 U 化工業安全作業資訊系統模組設計研究計畫 此一模組將提供工廠管理階層有效改進現行勞工安全領域中高職業傷害的缺點 研究主題將涉及現行工安作法及如何引進新的資訊科技, 實驗設計含括 Zigbee 網路拓鋪設計以及資料倉儲設計等議題 當然計畫內無線網路亦將與網際網路運用進行結合 文獻顯示, 大部分 U 化科技與 WIF 及行動裝置有關, 雖然 Zigbee 聯盟組織已經推廣許多自動控制與環境監控成功實例, 但是, 能夠妥善應用於工業安全領域的實例卻非常稀少 因此, 此一計畫應該是值得研究推廣主題 經過初步設計與測試, 本研究發現,Zigbee 是一種非常易於佈件且容易組裝的工業安全應用工具 但是, 資料正確率以及資料演算法是重要關鍵 本計畫以重心演算法方式進行標籤及讀取器相對位址計算依據, 相關設計應用介面也提供彈性讀取器設定方式及數量安排, 以便於後續修正工作進行 本計畫是國科會產學計畫一部分, 因此產學雙方皆因此受惠, 並帶領學生逐步運用 U 化案例於實際產業環境中 關鍵字 : Zigbee, 智慧型系統 醒吾技術學院資管系