CN110865036A - Rotary equipment monitoring platform and monitoring method based on spectral analysis - Google Patents
Rotary equipment monitoring platform and monitoring method based on spectral analysis Download PDFInfo
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- CN110865036A CN110865036A CN201911271278.1A CN201911271278A CN110865036A CN 110865036 A CN110865036 A CN 110865036A CN 201911271278 A CN201911271278 A CN 201911271278A CN 110865036 A CN110865036 A CN 110865036A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/17—Systems in which incident light is modified in accordance with the properties of the material investigated
- G01N21/25—Colour; Spectral properties, i.e. comparison of effect of material on the light at two or more different wavelengths or wavelength bands
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N35/00—Automatic analysis not limited to methods or materials provided for in any single one of groups G01N1/00 - G01N33/00; Handling materials therefor
- G01N35/00584—Control arrangements for automatic analysers
- G01N35/00722—Communications; Identification
- G01N35/00871—Communications between instruments or with remote terminals
Abstract
The invention discloses a monitoring platform and a monitoring method of rotating equipment based on spectral analysis, wherein the monitoring platform comprises an application cloud platform, a terminal information acquisition module, a central processing unit, an NFC chip and a communication module; the application cloud platform comprises a database, a basic management module, an equipment setting module, an equipment data expression module, an early warning module and mobile application software; the terminal information acquisition module comprises an NFC card reader and a handheld spectrometer; the NFC card reader, the central processing unit and the communication module are integrated on the handheld spectrometer; the handheld spectrometer is simple and convenient to operate, aims at lubricating oil, irradiates like an operation mode of a flashlight, and detects the lubricating oil to perform real-time physical examination on the rotating equipment. Compared with the traditional lubricating oil laboratory detection mode, the system has the greatest technical breakthrough of rapidness, real time and intelligence. The device can meet the requirements of rapid real-time detection of equipment lubricating oil in different environments. The lubricating oil detection efficiency is improved, and the detection cost is reduced.
Description
Technical Field
The invention relates to the field of monitoring equipment, in particular to a rotary equipment monitoring platform and a monitoring method based on spectral analysis.
Background
Currently, 64% of the world's electricity is consumed by motors, and the electricity produced by motors is higher; the rotating equipment is driven by electric power, fire power and organic fuel, so that the rotating equipment relates to aspects of industrial production and daily life, the rotating equipment (motor) comprises a bearing or a gearbox, the bearing or the gearbox is used as a core part of the rotating equipment (motor), and the rotating equipment can be down once the bearing or the gearbox is out of order. The normal operation of the rotating equipment plays a crucial role in production and life; the number of electrical machines worldwide is increasing at 9.5% per year, with rotating equipment being more, and most importantly, most rotating equipment being unmonitored or inconvenient to monitor, making it difficult to make a decision on the operation of the rotating equipment, and therefore, a failure of the rotating equipment, about 80% of which is caused by a bearing or gearbox failure, will have a significant impact on production and life. When the rotating equipment works, lubricating oil (grease) needs to be added to serve as a lubricant for a bearing or a gearbox, and as the rotation times of the bearing or the gearbox increase, the fine particles of the wear of the bearing or the gearbox accelerate the deterioration of the running environment of the bearing or the gearbox. The traditional bearing or gearbox monitoring methods are roughly divided into two types, one is that a conclusion is obtained by sampling and submitting lubricating oil of rotating equipment and detecting the lubricating oil by a physical or chemical method; for example, Chinese patent 'rolling bearing or gearbox defect detection device based on oil spectral analysis and magnetic flux leakage detection' (application number 2018113370325) needs sampling detection; the other is that the lubricating oil (grease) data is obtained by monitoring the embedded device in the rotating equipment; the former detection data is very troublesome and obviously not suitable for actual production and use, and the latter detection data is obviously not suitable for equipment which is produced and delivered from a factory, even if a sensor or a probe is added in the production process of the rotating equipment, the measured data may have larger errors due to the working stability of the embedded device, and the embedded device is quite troublesome to replace and cannot be replaced by a user of the rotating equipment.
At present, the rotating equipment is still manufactured and used in a traditional mode, the running condition of the rotating equipment is rarely monitored, and for rotating equipment manufacturers and rotating equipment users, an effective data acquisition method is lacked for the actual working condition of the rotating equipment, so that after the rotating equipment breaks down, the fault cause can be judged only according to surface phenomena and experience (different from person to person), and an end customer cannot perform preventive 'physical examination' on the rotating equipment. In order to ensure the normal operation of the rotating equipment, a terminal customer often adopts a regular maintenance method. While the manufacturer of the rotating equipment has no knowledge about the operation status of the rotating equipment. Therefore, there is a need for a monitoring method for monitoring bearings or gearboxes of rotating equipment.
Disclosure of Invention
The present invention aims to solve the above problems and provide a monitoring platform for a rotating device based on spectral analysis. The core point of the invention is a monitoring platform for processing and analyzing a mathematical model by hyperspectral remote sensing data established on the basis of a hyperspectral image processing and analyzing system, a data model is established by accumulating lubricating oil (grease) of a bearing or a gearbox of rotating equipment, the larger the established database is along with the increase of monitoring data, the analysis of newly acquired data by taking data accumulation modeling as reference is realized, meanwhile, the modeling of related data of the measurement of wear particles of the running bearing or the gearbox is actively added into the lubricating oil, the newly acquired data is classified, and the effective prediction and supervision of a motor are realized. Under the situation that the digitalized supervision is used as a core, a platform frame is built for different equipment manufacturing enterprises and different equipment users, effective supervision of the rotary equipment manufacturing enterprises on the equipment and effective supervision of the equipment users on different manufacturer equipment are achieved through a network communication technology, comprehensive datamation of the manufacturers, the users, managers and operators is achieved, early warning is carried out in advance, active operation and maintenance are achieved, and the motor fault occurrence rate is reduced. The method comprises the following specific steps:
a spectrum analysis-based rotating equipment monitoring platform comprises an application cloud platform, a terminal information acquisition module, a central processing unit, an NFC chip and a communication module; the application cloud platform comprises a database, a basic management module, an equipment setting module, an equipment data expression module, an early warning module and mobile application software; the terminal information acquisition module comprises an NFC card reader and a handheld spectrometer; the NFC card reader, the central processing unit and the communication module are integrated on the handheld spectrometer, the handheld spectrometer can complete identity authentication on the detection equipment, and NFC chip information is read through the NFC card reader; the NFC chip is attached to the monitoring rotary equipment in a film mode, the NFC chip is endowed with unique identity information UID, through setting the unique identity information UID, information of the monitored rotary equipment can be read through an NFC card reader (sub-categories are set on an application cloud platform and comprise factory information of the equipment, historical records and application scenes related to detected lubricating oil), further, identity information is endowed to data collected by the handheld spectrometer, so that the measured data can be classified, managed and analyzed (data measured at different times of the equipment of the same model or the same equipment), and the health state of the equipment can be inquired and detected through the application (mobile) terminal. The NFC card reader reads NFC chip information and forms a switch for starting the handheld spectrometer; for the condition that the information reading of the NFC chip is unsuccessful or unauthorized, the handheld spectrometer cannot be started, namely, the data measured by the handheld spectrometer is ensured to have unique identity information, so that the detected data has identity value, each acquired data can trace to the source in the analysis and comparison of a large amount of data, and the running condition of corresponding rotating equipment is judged. The central processing unit encodes data acquired by the handheld spectrometer, the communication module transmits data to the application cloud platform and the central processing unit, the communication module transmits digital signals to the application cloud platform through the internet to construct an acquired sub-database, and further the communication module receives data to perform system upgrading on the handheld spectrometer; and the application cloud platform decodes and analyzes the received data. The cloud platform is used for classifying the received digital signals according to the application scenes of the NFC chip UID, decoding is carried out, the decoding comprises methods such as regression curve fitting and fast Fourier transform, and the expression format of the acquired data is calculated; and calculating a characteristic value sequence (curve) of the lubricating oil according to the reflection spectrum of the lubricating oil, and corresponding to physical components in the lubricating oil according to a reflection wave band (frequency) and energy (amplitude). And (3) enabling the analysis result to correspond to a sub-database detection standard based on an application scene, and judging the health state of a bearing or a gearbox of the rotating equipment by combining the application scene.
As a further improvement of the above technical solution:
the handheld spectrometer is a battery-driven portable spectral imaging system.
The handheld spectrometer collects spectral data by detecting lubricating oil of a bearing or a gearbox of a rotating device, and is a portable spectral imaging system. The real-time qualitative detection of metal dust and other components in bearing of rotating equipment or lubricating oil (grease) of a gearbox is applied, so that the abrasion and 'health' state of the running equipment can be evaluated and judged. The handheld spectrometer can be used as an internet of things sensor, collects lubricating oil/grease spectrums, transmits the lubricating oil/grease spectrums to an application cloud platform, and feeds back results to a rotating equipment user in time through data processing. The central processor encodes the spectral data. The central processing unit converts the analog signal format of gathering into digital signal, to large batch rotating equipment control, in the operation process of patrolling and examining of reality, is that a handheld spectrum appearance detects many rotating equipment, and the data of gathering contain multiple information, encodes the data of gathering, reduces communication module's data transmission volume, has also reduced the hardware requirement to communication module simultaneously.
The database comprises a plurality of sub-databases, and the central processing unit uploads the spectral data to the application cloud platform to construct a collection sub-database. Collecting a plurality of rotating equipment bearing or gearbox lubricating oil samples to perform spectrum detection to obtain spectrum data and establishing an application scene sample sub-database; and establishing a relation between the application scene (which metal dust particles are determined to be detected) sample sub-database and an experimental sub-database standard pair model (modeling the spectral reflectivity and the characteristic curve of the standard oil sample), and differentiating the result of the application scene lubricating oil. The application scenario is determined by the UI D within the NFC chip (the system software device management module binds the application scenario and NFC at initialization). Adding metal particles with various particle sizes into lubricating oil, uniformly oscillating by ultrasonic waves, and carrying out spectrum detection on the obtained spectrum data to construct an experiment sub-database. The method comprises the steps of determining that metal dust particles possibly exist in lubricating oil through an application scene, establishing a sample sub-database taking the application scene as a unit after the lubricating oil is paired with a laboratory standard oil product, and continuously accumulating the sample sub-database taking the application scene as a basic unit (the paired standard oil product in the laboratory is used for pairing with the laboratory standard oil product). According to the application scene, the standard oil product in a laboratory can be determined, metal particles with specified granularity are added into national standard lubricating oil to be uniformly subjected to ultrasonic oscillation, and the spectral data obtained by spectral detection constitute an experiment sub-database with the application scene. Therefore, the database is a long benchmarking model which is continuously updated according to different application scenes, the collected data of the sub-database can also be used as a sample to become a part of the sample sub-database, and in the actual use process, the invention is increased along with the use time, the corresponding scenes are more, and the sample sub-database and the experimental sub-database of the corresponding scene are also continuously iterated.
The invention only carries out qualitative analysis on the comparison between the collected data of the bearing or the gearbox of the rotating equipment and the database and the modeling, reduces the precision of each data, and can judge the running condition of the bearing or the gearbox of the rotating equipment by setting a threshold value (alarm) or a boundary condition (warning). By constructing a database and/or a mathematical model, simultaneously accumulating and collecting the sub-databases continuously, expanding the database continuously, taking an analysis result as a data reference value, balancing error parameters and carrying out iterative optimization, the database has a self-learning function, and the acquired data in the later period can be judged more quickly and accurately.
The metal comprises one or more of aluminum-Al, cadmium-Cd, chromium-Cr, copper-Cu, iron-Fe, lead-Pb, magnesium-Mg, manganese-Mn, molybdenum-Mo, nickel-Ni, silver-Ag, tin-Sn, titanium-Ti, vanadium-V, zinc-Zn. The bearing or the gearbox of the rotating equipment and the parts installed on the bearing or the gearbox are basically made of iron-based alloy and contain various metal elements, when the bearing or the gearbox works, abraded micro particles enter lubricating oil, and corresponding spectral parameters are obtained through spectral measurement of the various metal elements in the lubricating oil.
The basic management module comprises organization management, department management, user management and user role management; the organization management comprises data classification management of different rotating equipment manufacturers and/or rotating equipment; the different manufacturers and different devices of the same manufacturer are distinguished and classified, a manufacturer sub-category is established by organization management, and a second sub-category is established according to the manufacturer sub-category, so that the manufacturers and corresponding terminal devices can be conveniently managed. The department management comprises organization and authority authorization of the management user and subordinate users thereof; after the client is authorized, the subordinate user can set the threshold value or boundary condition of the lubricating oil of the bearing or the gearbox of the rotating equipment according to the application scene, the operation data can be transmitted to an equipment maintenance unit in real time to carry out diagnosis and active maintenance decision, and the condition of early warning or fault alarm is determined. The user management provides data docking, pushing and remote monitoring services for the client; and the user manages the classified using terminals of the same equipment and different scenes. And the user role management establishes an operation remote supervision management platform for the equipment manufacturer and the client. The platform role management can be set by a device manufacturer as a first party, or by a device user as a first party, and the rotating device monitoring platform based on spectral analysis can also be set as a third-party service, so that the Internet of things motor platform has a wide application range.
The device comprises an NFC chip UID, a device setting module, an early warning module, a communication module, a relay device, a warning module and a warning module, wherein the device setting module is responsible for initializing binding of the NFC chip UID and a detected device, and comprises binding of an application scene, so that metal dust particles contained in lubricating oil along with operation and device loss are evaluated, the early warning module sets a threshold value or a boundary condition according to spectrum detection data, the device setting module and the early warning module form an early warning reaction structure, the early warning module comprises a fault warning pushing mechanism of an application cloud platform and a warning device installed in the communication module, when acquired data parameters are close to a warning threshold value or close to the boundary condition, the cloud platform is used for sending early warnings (short messages, WeChat, mails and calls), when the acquired data parameters exceed a fault specified threshold value, the cloud platform is used for sending fault warnings (short messages, WeChat and calls), the device is automatically stopped to operate under the control of the corresponding relay device according to the fault warning setting, safety is ensured, the setting of the threshold value and the boundary condition is that the warning β in the communication platform and the warning device and the warning module and the warning device can conveniently display the warning of a working terminal (an LED) at the client) and the warning terminal).
The device data expression module comprises visual collected data display and corresponding devices and time, and displays the data on the application cloud platform and the authorized client in real time. And the mobile client (the smart phone) displays the running state of the rotating equipment in real time after authorization, wherein the running state depends on the evaluation of the bearing or gearbox lubricating oil detection and comparison of the rotating equipment. The representation method emphasizes comprehensive data display, data position, data collection time and equipment operation state and visualization in the application cloud platform. The device operating state may then be emphasized at the mobile client. The device data will be displayed in the form of a plot of time versus horizontal axis (reflection band, i.e., frequency, energy, i.e., amplitude) while including a data log. The cloud platform is used for converting received digital information into analog signals, recovering acquired data, screening effective information, selecting data capable of evaluating the operation of the bearing or the gearbox, and converting the data into a visual curve.
The mobile application software is installed on the mobile client, and the running state of the equipment is started and displayed by scanning the unique code after being managed and authorized by the department. The mobile application software is installed on the smart phone, and the running state of the equipment is started and displayed through the QR (generated by the application cloud platform) on the mobile client scanning equipment. An authorized handset client can manage or set threshold (alarm) or boundary condition (warning) conditions for operating the device. The application cloud platform may authorize client users and assign device supervision tasks.
The mobile application software runs and operates under the conditions of local area network/3G/4G/5G/WiFi. Under the condition that the communication module and the application cloud platform are disconnected, the mobile application software is connected with the communication module to receive and store the acquired information to the mobile client, and then the mobile client transmits the received data to the application cloud platform.
A rotating equipment monitoring method based on spectral analysis comprises the following steps:
s1: attaching an NFC chip film to the surface of a shell of the monitoring rotary equipment, and binding the rotary equipment to be monitored through a fixed NFC chip; registering an application scene (device type) on an application cloud platform through initial setting;
s2: the handheld spectrometer reads the unique identity information UID of the NFC chip through the NFC card reader, completes unlocking of the handheld spectrometer and starts the handheld spectrometer; the NFC card reader reads a secret key of the handheld spectrometer formed by the NFC chip, and the handheld spectrometer can be started only after effective decryption is obtained; ensuring the identity of the measured data so as to construct a database and sort management and simultaneously forming a log of the detected equipment;
s3: performing spectrum detection on the lubricating oil for monitoring the bearing or the gearbox of the rotating equipment by using the handheld spectrometer to obtain spectrum data; the hyperspectral detection is adopted to carry out spectrum detection on the bearing or gearbox lubricating oil, a characteristic value sequence (curve) of the lubricating oil is calculated according to the reflection spectrum of the lubricating oil, and spectrum data are obtained according to the reflection wave band (frequency) energy (amplitude) corresponding to physical components in the lubricating oil; and binding the data with the NFC chip UID for uploading; enabling the uploaded data to have identity information;
s4: encoding the spectral data obtained in the step S3 through a central processing unit, and uploading the encoded spectral data to an application cloud platform through a communication module; the central processing unit converts the analog signal format into a digital signal, performs necessary data conversion coding compression on the digital signal, and then pushes the digital signal to the communication module, and the communication module transmits the digital signal to the application cloud platform through the internet;
s5: after receiving the data uploaded by the communication module, the application cloud platform decodes the data, retrieves a corresponding application scene according to the UID of the NFC chip, and differentiates the application scene with a relative application scene database and the standard pair data; the cloud platform is used for decoding the received digital signals, the data decoding comprises methods such as regression curve fitting, fast Fourier transform and the like, the expression format of the collected data (reflection wave band (frequency) and energy (amplitude)) is calculated, and then the data are aligned with a database (laboratory detection standard);
s6: evaluating the impurity content grade of the lubricating oil of the bearing of the transfer equipment according to the result of the step S5, and judging the running condition of the bearing or the gearbox according to the impurity content grade; and after the collected data are aligned with a database or a laboratory detection standard, the health state of the rotating equipment is evaluated by combining an application scene.
As a further improvement of the above technical solution:
the database of step S5 includes a plurality of sub-databases;
the spectrum data collected by the handheld spectrometer during monitoring form a collection sub-database according to an application scene (NFC UID); collecting a plurality of rotating equipment bearing or gearbox lubricating oil samples which have already operated according to an application scene to carry out spectrum detection, and establishing an application scene sample sub-database by using the measured spectrum data; adding metal particles with various particle sizes into lubricating oil, uniformly oscillating by ultrasonic waves, and carrying out spectrum detection to obtain spectrum data to form an experiment sub-database.
Further, the method comprises the following steps of; the method comprises the steps of determining metal dust particles possibly contained in lubricating oil through an application scene, establishing an experiment sub-database taking the application scene as a unit after the lubricating oil laboratory marks, and continuously accumulating a sample sub-database (passing the laboratory standard oil product mark) taking the application scene as a basic unit. The laboratory standard oil product generated according to the application scene can be added into national standard lubricating oil by metal particles with specified particle size to be ultrasonically oscillated uniformly, and the spectral data obtained by spectral detection forms an experiment sub-database with the application scene.
The invention only carries out qualitative analysis on the comparison between the collected data of the bearing or the gearbox of the rotating equipment and the database and the modeling, reduces the precision of each data, and can judge the running condition of the bearing or the gearbox of the rotating equipment by setting a threshold value (alarm) or a boundary condition (warning). By constructing a database and/or a mathematical model, simultaneously accumulating and collecting a sub-database and/or a sample sub-database and an experimental sub-database continuously, expanding the database continuously, taking an analysis result as a data reference value, balancing error parameters and performing iterative optimization, so that the database has a self-learning function, and the acquired data in the later period can be judged more quickly and accurately.
Has the advantages that:
1. the handheld spectrometer is simple and convenient to operate, aims at lubricating oil (grease), irradiates once like the operation mode of a flashlight, and detects the lubricating oil to perform real-time physical examination on the rotating equipment. Compared with the traditional lubricating oil laboratory detection mode, the system has the greatest technical breakthrough of rapidness, real time and intelligence. The device can meet the requirements of rapid real-time detection of equipment lubricating oil in different environments. The lubricating oil detection efficiency is improved, and the detection cost is reduced.
2. The detection platform only aims at the bearing or the gearbox of the rotating equipment, carries out qualitative analysis on the motor bearing or the gearbox, and can quickly and qualitatively judge the running state of the rotating equipment. When a plurality of rotating equipment are monitored or more equipment needs to be monitored, the method has a particularly strong advantage, establishes data identity information through identity authentication before each monitoring, and then monitors, is simple, convenient and quick, realizes effective monitoring of the rotating equipment by an equipment user or an equipment manufacturer, better realizes active operation and maintenance, solves the blank of effectively monitoring the operation of the rotating equipment at present, and greatly reduces the occurrence rate of equipment downtime due to faults.
3. The mass rotating equipment is rapidly and effectively monitored, the cloud platform is used for monitoring the rotating equipment produced by different types and different manufacturers, and a database is built and modeled according to the same type of electric mechanism. As the operational data accumulates, a model (operational state curve) of the normal operation of the application scenario of the device is built up. According to the model, the active maintenance can be carried out on each monitored independent motor or equipment in combination with application scene setting according to the monitored abnormal phenomenon.
4. Collected data are coded and converted into digital signals through the central processing module for transmission, the size of transmitted data is reduced, compared with unprocessed data, the transmission speed of the processed data is thousands of times of orders of magnitude faster, and for large-batch data transmission and reception, the requirements on hardware after coding processing are greatly reduced.
5. In order to realize effective data acquisition and effective monitoring of the rotating equipment, the rotating equipment is numbered through a uniform unique identification code, and the arrangement of an acquired data number list is realized. For the rotating equipment which is used, the unique identification code binds the parameters of the motor and serves as a retrieval code of the motor, and the mobile information acquisition module can be bound by scanning the code, so that the method is quick and convenient.
6. The communication module has the functions of receiving and sending data and can be connected with an external network to receive data so as to grade the motor operation monitoring device; when the intelligent device is disconnected with an external network, the communication module opens the hot spot, accesses the authorized intelligent device, transmits data to the accessed intelligent device, and transmits the data to the rear platform after the intelligent device receives the data. Meanwhile, the intelligent equipment can also perform a certain amount of decoding, and when the motor breaks down or the monitored data reaches a critical threshold value, the intelligent equipment performs rapid emergency treatment on the motor through decoding.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic diagram of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be described in detail below. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the examples given herein without any inventive step, are within the scope of the present invention. In the embodiment, a WL9A direct-reading spectrometer and a CCD full-spectrum direct-reading spectrometer which are produced by Shanghai Yifeng precision instruments, Inc. are adopted to measure the related spectral data.
As shown in fig. 1, the spectrum analysis-based monitoring platform for a rotating device of the present embodiment includes an application cloud platform, a terminal information collection module, a central processing unit, an NFC chip, and a communication module; the application cloud platform comprises a database, a basic management module, an equipment setting module, an equipment data expression module, an early warning module and mobile application software; the terminal information acquisition module comprises an NFC card reader and a handheld spectrometer; the NFC card reader, the central processing unit and the communication module are integrated on the handheld spectrometer; the NFC chip is pasted on the monitoring rotary equipment through a film, NFC chip information is read through an NFC card reader, the handheld spectrometer is unlocked, the handheld spectrometer is started, and data measured by the handheld spectrometer is also marked to be provided with unique identity information UID of the NFC chip; the collected data is processed by data coding through a central processing unit; after data of the central processing unit are coded, pushing the coded data to a communication module, and transmitting the data to an application cloud platform by the communication module; and decoding and analyzing the received data by using the cloud platform.
Further, the method comprises the following steps of; the handheld spectrometer collects spectral data by detecting bearing or gearbox lubricating oil of the rotating equipment through the hyperspectral transmitter, and applies real-time qualitative detection on metal dust and other components contained in the bearing or gearbox lubricating oil (grease) of the rotating equipment, so that the state of abrasion and health of operating equipment is evaluated and judged. About 80% of faults of the rotating equipment are caused by the bearing or the gearbox, and the bearing or the gearbox is detected, so that the running condition of the rotating equipment can be judged quickly. The central processing unit converts the acquired analog signal format into a digital signal, and reduces the data transmission quantity of the communication module.
Further, the method comprises the following steps of; the database comprises a plurality of sub databases based on application scenes, and the central processing unit uploads the spectral data bound with the NFC chip UID to the application cloud platform to retrieve the corresponding collected sub databases; collecting a plurality of rotating equipment bearing lubricating oil samples to perform spectrum detection to obtain spectrum data and establishing an application scene sample sub-database; adding metal particles with various particle sizes into lubricating oil, uniformly oscillating by ultrasonic waves, and carrying out spectrum detection to obtain spectrum data to form an experiment sub-database. The database is used as a reference value of the collected data to judge the operation condition of the rotating equipment.
Further, the method comprises the following steps of; the metal comprises one or more of aluminum-Al, cadmium-Cd, chromium-Cr, copper-Cu, iron-Fe, lead-Pb, magnesium-Mg, manganese-Mn, molybdenum-Mo, nickel-Ni, silver-Ag, tin-Sn, titanium-Ti, vanadium-V, zinc-Zn. The spectral data of each component in the lubricating oil is directionally measured by an experimental method or a sampling method, and the data detected in two directions by the experimental method or the sampling method is closer to the standard characteristic value, so that the characteristic values of various elements in the lubricating oil are determined by the method.
Further, the method comprises the following steps of; the basic management module comprises organization management, department management, user management and user role management; the organization management establishes manufacturers (sub-categories) and equipment models (secondary sub-categories) for classification management; the department management comprises organization and authority authorization of a management user and subordinate users thereof, and after the user (client) is authorized, the user can access the communication module, receive corresponding authorization data of the application cloud platform and set corresponding threshold values; the user management provides data docking, pushing and remote monitoring services for the client; the user role management establishes an operation remote supervision management platform for equipment manufacturers and clients. The platform can set a rotary equipment manufacturer as a first party, can also set a user as the first party, and can also set the platform as a third party to establish data relation between the rotary equipment manufacturer and the user, thereby realizing effective communication between the rotary equipment manufacturer and the user and providing a data base for active operation and maintenance of rotary equipment.
Further, the method comprises the following steps of; the platform establishes a database of manufacturers (sub-categories) and equipment models (secondary sub-categories) for the rotary equipment manufacturers, and provides a basis for technical improvement for the manufacturers.
Further, the method comprises the following steps of; the platform of the invention establishes a database of manufacturers (sub-categories) and equipment models (secondary sub-categories) for a user of the rotary equipment, and realizes effective management and active operation and maintenance of the rotary equipment of different manufacturers and different models.
Further, the method comprises the following steps of; the device setting module sets a threshold or a boundary condition according to the spectrum detection data; the equipment setting module and the early warning module form an early warning reaction structure; the early warning module sends out early warning (short message, WeChat, mail and telephone) and an alarm (LED warning lamp and sound) arranged in the communication module by using the cloud platform.
Further, the method comprises the following steps of; the device data expression module comprises visual collected data display and corresponding devices and time, and displays the data on the application cloud platform and the authorized client in real time. And viewing the corresponding detection data and evaluation conclusion through the mobile phone APP or the client. The device data will be displayed in the form of a plot of time versus horizontal axis (reflection band, i.e., frequency, energy, i.e., amplitude) while including a data log.
Further, the method comprises the following steps of; the mobile application software runs and operates under the conditions of local area network/3G/4G/5G/WiFi. Under the condition that the communication module and the application cloud platform are disconnected, the mobile application software (APP) is connected with the communication module to receive and store the acquired information to the mobile client, and then the mobile client transmits the received data to the application cloud platform.
The embodiment also discloses a rotating equipment monitoring method based on spectral analysis, which comprises the following steps:
s1: recording unique identity information UID (user identification) into an NFC chip, and attaching an NFC chip film to the surface of a shell of rotary equipment to be monitored; establishing unique contact between the recorded unique identity information UID and the corresponding rotating equipment on the application cloud platform; the unique identity information UID is used as an unlocking key of the handheld spectrometer;
s2: the handheld spectrometer reads the unique identity information UID of the NFC chip through the NFC card reader, completes unlocking of the handheld spectrometer and starts the handheld spectrometer;
s3: performing spectrum detection on the hyperspectral transmitter of the handheld spectrometer to the bearing lubricating oil of the monitoring rotating equipment, and obtaining a characteristic value sequence (curve) of the lubricating oil according to the reflection spectrum of the lubricating oil;
s4: encoding the reflection spectrum data obtained in the step S3 through a central processing unit, binding the data with an NFC chip UID, and uploading the data to an application cloud platform through a communication module;
s5: after receiving the data uploaded by the communication module, the application cloud platform decodes the data and performs data standard pair with the database; analyzing physical components in the lubricating oil according to reflection wave band (frequency) energy (amplitude), and performing calibration on analysis results corresponding to a database (laboratory detection standard);
s6: and evaluating the impurity content grade of the lubricating oil of the bearing of the transfer equipment according to the result of the step S5, and judging the running condition of the bearing according to the impurity content grade.
Further, the method comprises the following steps of; the database of step S5 includes a plurality of sub-databases;
the spectrum data collected by the handheld spectrometer during monitoring form a collection sub-database; collecting a plurality of rotating equipment bearing lubricating oil samples which are already running for spectrum detection, and establishing an application scene sample sub-database by using the measured spectrum data; adding metal particles with various particle sizes into lubricating oil, uniformly oscillating by ultrasonic waves, and carrying out spectrum detection to obtain spectrum data to form an experiment sub-database. By constructing a database and/or a mathematical model, simultaneously accumulating and collecting a sub-database and/or a sample sub-database and an experimental sub-database continuously, expanding the database continuously, taking an analysis result as a data reference value, balancing error parameters and performing iterative optimization, so that the database has a self-learning function, and the later-stage collected data is qualitatively judged more quickly and accurately. And making active operation and maintenance according to qualitative results, such as oil filling, oil changing, maintenance, immediate replacement and the like of the bearing.
The technical solutions of the embodiments of the present invention can be combined, and the technical features of the embodiments can also be combined to form a new technical solution.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of the changes or substitutions within the technical scope of the present invention, and all the changes or substitutions should be covered within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the appended claims.
Claims (10)
1. A rotating equipment monitoring platform based on spectral analysis is characterized in that: the system comprises an application cloud platform, a terminal information acquisition module, a central processing unit, an NFC chip and a communication module; the application cloud platform comprises a database, a basic management module, an equipment setting module, an equipment data expression module, an early warning module and mobile application software; the terminal information acquisition module comprises an NFC card reader and a handheld spectrometer; the NFC card reader, the central processing unit and the communication module are integrated on the handheld spectrometer; the NFC chip is attached to the monitoring rotating equipment through a film, and the NFC chip is endowed with unique identity information UID; the NFC card reader reads NFC chip information and forms a switch for starting the handheld spectrometer; the central processing unit encodes the data collected by the handheld spectrometer; the communication module is used for transmitting data between the application cloud platform and the central processing unit; and the application cloud platform decodes and analyzes the received data.
2. The spectroscopic analysis-based rotating equipment monitoring platform of claim 1, wherein: the handheld spectrometer collects spectrum data by detecting bearing or gearbox lubricating oil of the rotating equipment, and the central processing unit encodes the spectrum data.
3. The spectroscopic analysis-based rotating equipment monitoring platform of claim 2, wherein: the database comprises a plurality of sub-databases, and the central processing unit uploads the spectral data to an application cloud platform to construct a collection sub-database; collecting a plurality of rotating equipment bearing or gearbox lubricating oil samples to perform spectrum detection to obtain spectrum data and establishing an application scene sample sub-database; adding metal particles with various particle sizes into lubricating oil, uniformly oscillating by ultrasonic waves, and carrying out spectrum detection to obtain spectrum data to form an experiment sub-database; and establishing a relation between the application scene sample sub-database and the experimental sub-database standard pair model according to the application scene sample sub-database, thereby differentiating the result of the application scene lubricating oil.
4. The spectroscopic analysis-based rotating equipment monitoring platform of claim 3, wherein: the metal comprises one or more of aluminum-Al, cadmium-Cd, chromium-Cr, copper-Cu, iron-Fe, lead-Pb, magnesium-Mg, manganese-Mn, molybdenum-Mo, nickel-Ni, silver-Ag, tin-Sn, titanium-Ti, vanadium-V, zinc-Zn.
5. The spectroscopic analysis-based rotating equipment monitoring platform of claim 1, wherein: the basic management module comprises organization management, department management, user management and user role management; the organization management comprises data classification management of different rotating equipment manufacturers and/or rotating equipment; the department management comprises organization and authority authorization of the management user and subordinate users thereof; the user management provides data docking, pushing and remote monitoring services for the client; and the user role management establishes an operation remote supervision management platform for the equipment manufacturer and the client.
6. The spectroscopic analysis-based rotating equipment monitoring platform of claim 1, wherein: the device setting module sets a threshold or a boundary condition according to the spectrum detection data while binding the application scene; the equipment setting module and the early warning module form an early warning reaction structure; the early warning module comprises a fault alarm pushing mechanism of the application cloud platform and an alarm installed in the communication module.
7. The spectroscopic analysis-based rotating equipment monitoring platform of claim 1, wherein: the device data expression module comprises visual collected data display and corresponding devices and time, and displays the data on the application cloud platform and the authorized client in real time.
8. The spectroscopic analysis-based rotating equipment monitoring platform of claim 1, wherein: the mobile application software runs and operates under the conditions of local area network/3G/4G/5G/WiFi.
9. A rotating equipment monitoring method based on spectral analysis is characterized by comprising the following steps:
s1: attaching an NFC chip film to the surface of a shell of monitoring rotary equipment;
s2: the handheld spectrometer reads the unique identity information UID of the NFC chip through the NFC card reader, completes unlocking of the handheld spectrometer and starts the handheld spectrometer;
s3: performing spectrum detection on the lubricating oil for monitoring the bearing or the gearbox of the rotating equipment by using the handheld spectrometer to obtain spectrum data, and binding the data with an NFC chip UID for uploading;
s4: encoding the spectral data obtained in the step S3 through a central processing unit, and uploading the encoded spectral data to an application cloud platform through a communication module;
s5: after receiving the data uploaded by the communication module, the application cloud platform decodes the data, retrieves a corresponding application scene according to the NFC chip UID, and marks data difference with the relative application scene sample sub-database and the experimental sub-database;
s6: and evaluating the impurity content grade of the lubricating oil of the bearing of the transfer equipment according to the result of the step S5, and judging the running condition of the bearing or the gearbox according to the impurity content grade.
10. The method of claim 9, wherein the step of monitoring the rotating device comprises: the database of step S5 includes a plurality of sub-databases;
establishing a collection sub-database for spectral data collected by the handheld spectrometer during monitoring; collecting a plurality of rotating equipment bearing or gearbox lubricating oil samples to perform spectrum detection to obtain spectrum data and establishing an application scene sample sub-database; adding metal particles with various particle sizes into lubricating oil, uniformly oscillating by ultrasonic waves, and carrying out spectrum detection to obtain spectrum data to form an experiment sub-database.
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