Factory Park Monitoring Splice Screen Scheme

From the signal list of two types of tasks, dual-path architecture, screen number backstepping and decoding conversion, to multi-plant convergence, factory type difference, three-network isolation, budget trade-off and source factory value, the landing judgment of the splicing screen of the factory park monitoring center is given.

The most expensive mistake in the monitoring and splicing screen scheme in the factory park is not that the screen is expensive to buy, but that "the security and production kanban are stuffed into the same set of decoders. As a result, the number of video paths is not enough, the kanban is refreshed and the cross-network docking is stuck by the security review".The essential difference between the factory monitoring center and the general park security center is that it simultaneously carries two types of tasks that are completely different in nature:Security guardThe monitoring is the space (perimeter, entrance and exit, warehouse, hazardous chemicals area), take the video platform to take the stream decoding;Production and operation situationThe process (production line status, equipment OEE, plan achievement rate) is monitored, and MES/SCADA application screen acquisition is taken. The two links occupy different resources, different responsible parties, and different specifications. If they are mixed together, problems will inevitably occur on one side. The more subtle risk is "fake real-time"-frozen video and stop-watch kanban are treated as real-time status, which may lead to wrong production or safety decisions. This article is carried out in the order of "task decomposition → signal list → screen number backstepping → decoding conversion → kanban wall → multi-factory convergence → factory type difference → three-net isolation → budget trade-off → on-site investigation and acceptance". each link gives calculable formulas and judgable thresholds, and explainsLCD splicing screen China source factoryThe actual value of direct supply in non-standard bracket customization, seam size combination and long-term spare parts supply.

1. selection decision order: eight steps, first task-by-task and then capacity.

The failure of the selection of the factory monitoring center is often not because a parameter is wrong, but because the sequence of links is out of order-first buy the screen and then think about the purpose, first set the budget and then divide the tasks, first match the decoder and then list the signals. A reusable chain of judgment is:

1. There are two types of tasks:Clarify the proportion of security duty and production and operation situation, and whether they share a wall.
2. List of column signals:Surveillance video, production kanban, access control/vehicle, fire/security alarm, item by item, source, access method, responsible party.
3. Count screens:Draw a draft window layout, use "window number ÷ split number" to reverse the number of screens, and then use the seat viewing distance to check the readability.
4. Number of fold decoding paths:According to the "screen number x constant display partition number" conversion, distinguish the total amount of access and at the same time readable; Kanban takes the acquisition link and does not account for video decoding.
5. Set the way to see the board on the wall:Source PC output or platform rendering straight out, select according to MES architecture, and verify the performance of the acquisition end.
6. Nuclear multi-plant convergence:Grouping plan, authority layering and video access bandwidth shall be confirmed according to platform conditions.
7. Do three-net isolation:The cross-network convergence path between video network, production network and office network shall be designed according to the requirements of safety review.
8. Compared with the quotation and inspection supplier:Sub-integrity and source factory customization/spare parts capabilities, with real picture acceptance.

2. is divided into two types of tasks: security monitoring is space, production kanban monitoring is the process

The two types of tasks of the factory monitoring center are not as simple as "all pictures. Their signal sources, wall links, resource occupation and specification requirements are completely different, and they must be separated before determining whether they are shared.

List of 3. signals: four types of signals, four links

The signal source of the factory monitoring center can be divided into four categories according to the wall link. It is the basic work of the scheme design to mark "source, access method and responsible party" item by item when making the list.

There are two kinds of structures on the wall of the kanban. If you choose the wrong one, you will get stuck.

The production of kanban walls is not as simple as "opening the web page and throwing it up. The two common architectures differ greatly:

• Source PC output mode: Open the MES/SCADA Kanban page on the PC connected to the large screen and output it to the splicing processor via HDMI. The advantage is that it is simple to realize and does not rely on platform transformation. The disadvantage is that each kanban needs a PC window. When multiple kanban boards are on the same screen, PC performance and window management become bottlenecks, and the resolution and refresh rate of kanban are limited by PC output capacity.
• Platform rendering straight out mode: The management platform configures the data source and directly renders the kanban screen and outputs it as a video stream. The advantages are unified management of multiple boards and better resolution matching. The disadvantage is that platform support is required, additional authorization may be involved, and the kanban data interface needs to be open.

Criteria for judgment: If the number of kanban boards is small (2-3 pieces) and the content is relatively fixed, the source PC mode can be established. If the number of kanban boards is large and frequent switching or dynamic refreshing is required, it is safer to render the platform directly, but it is necessary to confirm whether the platform supports it and whether MES opens the data interface.Either way, the wall demonstration must be made with the real MES page of the factory.Instead of using static screenshots-the rendering fluency of dynamic charts and maps can only be measured on real pages.

Counting the number of screens 4.: using the window draft to push back, not starting with "other people's house a few pieces"

The number of screens is not directly determined by "monitoring center area" or "budget", but by "how many readable windows need to be displayed at the same time. The starting point of the reverse thrust is aDraft window layout。

Three Steps and Formula of Reverse Thrust

1. Number of windows: How many key images (perimeter, gate, warehouse, hazardous chemicals area) do you need to monitor at the same time in security mode? How many kanban windows do you need in production mode (production line situation, KPI trend, detail tracing)? For example, security requires 16 key image rounds to patrol the area, and production requires 3 kanban windows and 1 detail window.
2. Number of converted screens: The key security picture is divided into 4 parts (4 windows per screen) and 9 parts for general round rounds. The production billboard uses the whole screen or 2 parts (to ensure that the text and trend chart are readable). The larger value shall be taken after conversion respectively, and rounded up to the common number of rows and columns such as 2 × 3, 3 × 3 and 3 × 4.
3. Check readability: Check with the nearest/farthest seat distance: whether the license plate and personnel characteristics in the security window can be identified; Can KPI numbers and trend lines in the kanban be seen clearly. If the farthest seat cannot see the text in the 9-split window clearly, reduce the number of splits or increase the number of screens; If the nearest seat is too close to make the seam obvious, adjust the screen wall position or seam level.

5. the number of folding decoding paths: distinguishing the total amount of access and simultaneous readable.

"Access to 500 Road" and "see 50 Road at the same time" are two different things. The decoder does not need to be bought according to the total number of cameras, but should be converted according to the "number of screens × number of constant display partitions" and distinguish three calibers:The total number of platform accesses, the number of simultaneous access flows, and the number of simultaneous decoding on the wall. The round tour is time-sharing switching and does not increase the upper limit of simultaneous display.

The new factory project should reserve 20%-30% decoding margin according to the growth of monitoring points in the next 2-3 years, and verify the platform forwarding concurrency and network bandwidth. The smallest of the three values is the actual number of channels that can be simultaneously displayed on the wall. Bandwidth estimation: number of concurrent paths × single-path code rate (H.265 1080P is about 2-4Mbps), and then overlay platform forwarding, storage backhaul and other service occupancy, leaving 30%-50% margin.

Multi-factory convergence in 6.: what to watch locally, what to watch in general control, and how to adjust the video

The monitoring of manufacturing enterprises is often distributed in multiple workshops or even multiple branches. The convergence of multiple factories is not as simple as "transmitting all the pictures to the headquarters", but to answer three questions: what the local duty watch, what the general control center watches, and how to match the video access rights and bandwidth.

7. factory type differences: chemical, electronics, food, logistics, automobile manufacturing are not the same set of configuration

"Factory Park" is a broad term, and the monitoring focus and Kanban requirements vary greatly from industry to industry. Sleeve all plants with the same solution is the most common over-configuration or under-configuration in plant projects.

The type of factory directly changes the focus of the plan: chemical projects are most afraid of "the alarm screen is cut off by patchwork" and "the equipment in explosion-proof area is not in conformity"; Electronic manufacturing is most afraid of "kanban refresh Caton" and "clean workshop installation pollution"; Food projects are most afraid of "failure of cold storage environmental equipment"; Logistics storage is most afraid of "insufficient bandwidth for multi-workshop convergence". The plan design shall confirm the plant type before deciding on the configuration basis of patchwork, brightness, panel grade and structure.

8. three-network isolation: cross-network convergence path of video network, production network and office network

The link that the factory monitoring center is most likely to be stuck in the safety review stage is "cross-network docking". Video monitoring is usually in the video private network, MES/SCADA in the production network, office system in the office network, the three networks have different security and isolation requirements, and all signal lines cannot be simply plugged into the same processor.

9. budget trade-offs and source plant value

The budget of the plant project varies greatly, but the risk of "winning the bid at a low price and adding items at a later stage" is widespread. When the budget is limited, the recommended order of trade-offs is:First, ensure the readability of the security display window (if the perimeter and hazardous chemicals area cannot be seen clearly, the security watch will lose its meaning), then ensure the collection performance of the wall on the kanban (kanban Caton, production command is the decoration), then set the seam according to the nearest viewing distance (3.5mm can be established at a distance above 2.5 meters), and finally consider the extra margin of brightness and consistency. Don't sacrifice the number of screens or the performance of the collection side for the sake of "0.1mm smaller patchwork"-the former is a plus for perception and the latter is the bottom line of the business.

Quotes must be itemized to account

• Screen: Specific model, panel source and grade (industrial grade A or ordinary grade A), patchwork specifications, brightness and resolution. If only "55-inch splicing screen" is written but not the model and grade, clarification is required.
• signal processing equipment: Decoder model and number of channels, processor input/output channels and windowing capabilities, number and configuration of Kanban acquisition workstations.
• Structure and installation: Bracket type (wall hanging/front maintenance hydraulic/floor cabinet/non-standard customization), load-bearing accounting, cable brand and length, and removal of old equipment.
• Cross-network and joint debugging: Safety isolation equipment, kanban data interface docking, multi-plant convergence configuration, alarm linkage joint debugging. This part is the most easy to miss the factory project.
• Service and Delivery: Commissioning scope (including kanban configuration and plan preparation), training sessions, quality assurance starting point, spare parts list and after-sales response time limit.

10. Site Investigation List and Core Items of Acceptance

The site conditions of the factory monitoring center directly determine whether the screen wall can be installed or not. The following checklist should be completed during the programme phase.

Core items of acceptance

• Security readability: Use the real monitoring screen of the plant area to show whether the nearest/farthest seat can identify the characteristics of personnel and vehicles according to the security layout.
• Kanban readability: Use the real MES/SCADA page of the factory to check whether KPI numbers, trend charts and status lights are continuously distinguishable at the seam, and whether dynamic refresh is smooth.
• Stop and freeze tips: Simulate that the kanban data stops updating and the video stream is interrupted, and check whether the large screen displays "data expired" or "signal exception" within the agreed time.
• Alarm linkage: Simulate the triggering of safety/fire alarm, measure the pop-up time, picture correctness, video marking, and restore layout; test the priority of two concurrent routes.
• Multi-plant convergence: Check the permission and response of the general control to see the delay of the picture of the branch factory, the switching of the group plan, and the video access.
• Continuous operation: Operate at full load for a specified period of time (e. g. 72 hours) without failure or performance degradation.

XI. Common Misunderstandings

• Myth 1: The production of kanban into the video decoder. Kanban is an application picture, which takes the acquisition link and does not occupy video decoding resources. The stuffing decoder not only wastes the number of decoding paths, but also may display abnormalities due to the mismatch of refresh methods.
• Misunderstanding 2: Buy decoders directly with "monitoring the number of roads. Factory 500-way monitoring does not mean that 500-way decoding is required. Decoding is converted according to "screen number x constant display partition number", and the upper limit of simultaneous rotation is not increased. Leave 20%-30% margin for new projects.
• Misunderstanding 3: Think that "you can watch videos when you gather". Multi-factory convergence solves real-time picture scheduling. Video access depends on platform and storage architecture, authority and bandwidth, and must be confirmed separately in the scheme stage.
• Misunderstanding 4: Cross-network docking "pick it up first". Direct connection between video network, production network and office network may be directly rejected by security review. The cross-network path must be approved by the owner, designed according to the enterprise security strategy, and the isolation equipment is included in the quotation.
• Myth 5: All factories have the same configuration. Chemical explosion-proof and alarm priority, electronic clean workshop and high refresh kanban, food cold storage moisture-proof, logistics of long-distance large space, car multi-workshop convergence-configuration logic is completely different.
• Misunderstanding 6: Use the demonstration film for acceptance, not the real picture. The supplier demonstrated high-contrast video and static kanban screenshots. The real monitoring screen and dynamic MES page effect of the factory are often much worse. Acceptance must use the factory's own content.
• Myth 7: Think the "source factory" is just cheap. The value of the source factory is in non-standard bracket customization, patchwork size combination and long-term spare parts supply. The assessment verifies factory qualifications and panel sources, rather than just looking at publicity.

XII. FAQ

XIII. Conclusion