CN101118437A - New style numerically controlled machine remote condition monitoring and failure diagnosis system realizing method - Google Patents
New style numerically controlled machine remote condition monitoring and failure diagnosis system realizing method Download PDFInfo
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- CN101118437A CN101118437A CNA2007100185703A CN200710018570A CN101118437A CN 101118437 A CN101118437 A CN 101118437A CN A2007100185703 A CNA2007100185703 A CN A2007100185703A CN 200710018570 A CN200710018570 A CN 200710018570A CN 101118437 A CN101118437 A CN 101118437A
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Abstract
The present invention discloses an implementation method of a long-distance state monitor and failure diagnosis system of a novel numerical control machine, and belongs to the numerical control machine, information processing, network technology, industrial control technology fields, and relates to the digital control technology, long-distance telemetry tracking and command, failure diagnosis, network communication, automatic control and signal processing, and mainly makes the use of the modern long-distance telemetry tracking and command technology and the failure diagnosis analysis technology, and combines the characteristics of the state monitor and failure diagnosis of the numerical control machine, and builds the method of the state monitor and failure diagnosis system of the novel numerical control machine based on the wired and the wireless internet.
Description
One. affiliated technical field
The invention belongs to numerically-controlled machine tool system, information processing, network technology, industrial control technology field, relate to digital control technology, remote measurement and control, fault diagnosis, network communication, control and signal Processing automatically, mainly be to utilize remote modern observation and control technology and Analysis on Fault Diagnosis technology, the characteristics of combining with digital control conditions of machine tool monitoring and fault diagnosis, set up one novel based on wired and numerically controlled machine remote condition monitoring and fault diagnosis system implementation method wireless internet network.
Two. background technology
Numerically-controlled machine is a kind of modern electromechanical equipment mechanical, electrical, liquid that integrates.The complicacy of Numeric Control Technology itself, the diversity of technology and the complicacy of processing parts, make the specification, various in style of digital control system, performance difference is very big, the controlled variable complexity, and debugging operations is loaded down with trivial details, therefore, in case numerically-controlled machine breaks down, it is carried out fault diagnosis and keeps in repair will be a professional very strong job, many times must rely on the support of numerically-controlled machine manufacturer to solve.So just cause the fault lathe often to can not get keeping in repair timely, prolonged the downtime, reduced the production efficiency of numerically-controlled machine.On the other hand, this also makes the technician of some digital control system manufacturers have to run around all the time wears him out, thereby has increased enterprise's after service cost.
Along with the develop rapidly of computer networking technology, and the extensive popularization of advanced manufacturing technology in the manufacturing, a lot of enterprises have set up the Informationization Manufacture network platform of oneself, have realized the networking of computing machine and various production equipments.Now, most digital control system manufacturer is integrated intelligent network interface in the digital control system of oneself producing, support digital control system and intranet, the perhaps connection of Global Internet, this is with regard to for using network to come numerically-controlled machine is carried out remote condition monitoring and fault diagnosis is laid a good foundation.
Native system adopts advanced remote measurement and control technology and fault detect/analysis/treatment technology, based on internet and wireless network, realizes the electronic product manufacturing enterprise after-sales service system of a new generation.Remote status diagnosis terminal and fault handling center that manufacturing enterprise finishes by this project, can " stay indoors " with regard to online, obtain its electric, mechanical movement state of selling product, early stage incipient fault and sent out failure message in real time, thereby guide product uses the maintenance personal of enterprise to keep in repair fast, perhaps sends the extremely strong a small amount of professional after sale service personnel of specific aim to finish fault handling and maintenance job.For production enterprise, adopt this new after sale service mode, can significantly reduce the workload of after-sales maintenance service and the expense of generation, improve the after sale service reaction velocity greatly, and reduce significantly product servicing time, this improves after sale service quality and efficient for production enterprise, enlarges popularity of enterprise and has very important significance; And for the enterprise that uses product; this novel mode will effectively realize preliminary examination, prediction; thereby effectively avoid the appearance of catastrophic failure; the time of reducing fault handling and maintenance of equipment greatly simultaneously; reduced the time of equipment downtime maintenance, maintenance significantly; realized that continuous, online equipment state detects, shut down, stop work the problem of handling failure to bring brand-new solution for reduce as far as possible.
Three. summary of the invention
Mainly be divided into following two parts based on wired and numerically controlled machine remote condition monitoring and fault diagnosis system wireless internet network: the one, NC machine tool state monitoring and fault pre-service terminal, mainly finish the status monitoring and the failure message preprocessing function at numerically-controlled machine scene, be placed on the numerically-controlled machine; The 2nd, the remote fault diagnosis center mainly realizes being placed in the function of expert system fault analysis and diagnosis on the server of numerically-controlled machine producer.Illustrated below in conjunction with accompanying drawing 1.
Left-hand component is the structure at numerically-controlled machine scene in the accompanying drawing 1, the core component that is used for status monitoring and fault diagnosis is NC machine tool state monitoring and fault pre-service terminal, this terminal is connected with current sensor etc. with vibration transducer (acceleration transducer), pressure transducer, temperature sensor, voltage by electric adaptable interface (comprising the signal condition part), these sensors are directly installed on the main position of numerically-controlled machine (as main shaft/feed shaft and bearing, motor, hydraulic transmission part, transmission cases etc.), direct-on-line detects the key message at these positions; Simultaneously by the digital control system intelligent communication interface, obtain the failure code of various electric state data of digital control system and appearance, comprehensively carry out the pre-service of various data, and utilize state analysis and fault handling technology, form status data and fault data bag, and break down or incipient fault in, utilize network that this packet is sent to the remote fault diagnosis center of numerically-controlled machine manufacturer, finish the function of remote condition monitoring and fault diagnosis terminal.
Right-hand component is the remote fault diagnosis center that is positioned at numerically-controlled machine producer in the accompanying drawing 1, this platform is by the status data and the failure code bag of INTERNET or each NC machine tool state monitoring terminal of the online acquisition of wireless network, the working data base of every numerically-controlled machine is gone in unloading, utilize expert system fault diagnosis storehouse simultaneously, carry out fault analysis, and can adopt the mode of virtual expert's remote medical consultation with specialists, the failure judgement content, and processing suggestion or method are provided, instruct numerically-controlled machine applying unit Technical Maintenance Staff or our factory's after-sales service personnel to carry out the maintenance of numerically-controlled machine.
Four. description of drawings
Accompanying drawing 1 is based on the numerically controlled machine remote condition monitoring of wired and wireless internet network and the structural drawing of fault diagnosis system.
Five. embodiment
1. the following embodiment of introducing two major parts at first respectively:
1) NC machine tool state monitoring and fault pre-service terminal
NC machine tool state monitoring and fault pre-service terminal are mainly finished the function of four parts, be respectively monitoring function, with information communication function, status data and fault data preprocessing function, the remote communicating function of digital control system.
First function is to monitor at the main signal that can reflect numerically-controlled machine motion state and process state, monitoring target mostly is main shaft, feed shaft, hydropneumatic equipment etc., and the signal of status monitoring mainly is divided into power, vibration, pressure, flow and temperature etc.
● the power signal monitoring is by parameters such as the input voltage of monitoring numerically-controlled machine and electric currents, the process state is monitored, the duty at these parameter reflection spindle motors, feeding motor, drive disk assembly, cutting position, its advantage is that antijamming capability is strong, is easy to obtain.The electrical quantity of monitoring mainly contains:
A) spindle motor: line voltage U, electric current I
m, rated output Pm=UI
m
B) other feeding motor: line voltage U, electric current I
x, rated output Px=UI
x
● the monitoring of vibration signal is the most frequently used monitoring parameter, and vibration signal has comprised relatively abundanter failure message.The acceleration signal a that the vibration signal monitoring is extracted
Ij(ij represents j position i axle) is:
A) main shaft position, feed shaft acceleration signal: a
Xm, a
Ym, a
Zm
B) other through-drive position, feed shaft acceleration signal: a
Xx, a
Yx, a
Zx
● temperature, pressure and flow signal can reflect the load in process of spindle motor, main spindle box, wearing and tearing, variation such as lubricated.The signal that signal monitorings such as temperature, pressure and flow extract is:
A) main shaft position: spindle motor temperature T
m, the warm T of main spindle box oil.
B) feed shaft position: other feed shaft feeding motor temperatures T
x, T
y, T
z...
C) pressure position: the bleed pressure P of air clamper
1, the hydraulic power source pressure P of whirligig
2, the hydraulic power source pressure P of hydraulic feed gearing
3
D) flow position: relevant portion flow signal in the hydraulic system
Second function is to carry out communication with digital control system or PLC, utilize the real-time communication interface (relatively more commonly used is to adopt the RS232/485 interface) of digital control system or PLC to obtain electric control system internal information and interface work state information, obtain the inner failure message that produces of digital control system or PLC simultaneously;
The 3rd function is at the various parameters, data and the information that obtain, comprehensively carry out the fault analysis pre-service, finding under the situation that may occur or break down, produce status data and fault data bag, as occur transfiniting at each monitor signal or jiggly situation under, and digital control system has been quoted under the situations such as fault.Signal pre-processing module is at different signal characteristics, can carry out time-domain analysis (dimensionless index, probability density, autocorrelation function, cross correlation function), frequency-domain analysis (power spectrum, cepstrum), time frequency analysis (wavelet transformation) and transient analysis (Bode figure, polar plot) to signal, also can carry out various trend analyses and forecast.
The 4th function is to set up with the INTERNET or the wireless network at numerically-controlled machine manufacturer remote fault diagnosis center to connect, effective data server that also reliably status data and fault data bag is transferred to the remote fault diagnosis platform.
2) remote fault diagnosis center
Remote diagnostic center is the core of whole remote failure diagnosis system, and it mainly is made up of remote diagnosis service routine and diagnostic expert system.
The remote diagnosis service routine is by network communication, and modules such as fault analysis and diagnosis, user management, knowledge base management and remote collaboration management are formed.
Wherein, the network communication module has realized the information interchange of status monitoring and fault diagnosis terminal, strange land main frame and remote diagnostic center, and it is the foundation stone of whole remote diagnosis system.Fault analysis, diagnostic module can be realized services such as online fault analysis, fault diagnosis, off-lined signal analysis and information inquiry.In native system, the core ingredient of fault analysis, diagnostic module is a fault diagnosis expert system that is based upon based on facility information.User management module is responsible for user's registration of total system, work such as user rs authentication.The knowledge base management module functions is exactly to be responsible for the interpolation of knowledge, to put in order and to satisfy fault analysis, the diagnostic module needs to knowledge.Concerning any one expert system, the importance of knowledge is self-explantory.The expert system based on unit in the past, its knowledge mainly by artificial input in advance, because the chance of " clinical " is few, accumulate the knowledge difficulty voluntarily, so its knowledge relative deficiency, the reliability of diagnosis is difficult to be guaranteed.Remote failure diagnosis system has successfully solved this problem, concerning diagnostic center. the equipment that spreads all over the world, in case break down, all can see a doctor in diagnostic center, and increased its " clinical " chance widely, increased accumulation of knowledge.Simultaneously, the expert of diagnostic center can increase the knowledge of oneself at any time easily in knowledge base, knowledge base is put in order, makes diagnosis become more effective.The main effect of remote collaboration administration module is to provide a network platform for the telereference diagnosis.When the system supplymentary diagnosis can not obtain under satisfied result or the unsatisfied situation of result of client to the system supplymentary diagnosis, the result that the remote collaboration administration module obtains device fault information, system supplymentary diagnosis etc. sends to default expert, and can be according to expert's requirement, set up communicating to connect of expert and production scene, make the expert can and field apparatus and technician between carry out the mutual of information, obtain diagnostic message more fully.
2. following introduction respectively is mainly soft, hardware module disposes and function:
1) NC machine tool state monitoring and fault pre-service terminal
A) hardware configuration
NC machine tool state monitoring and fault pre-service terminal mainly are made up of embedded computer (comprising the multi-functional acquisition module of signal), signal condition module, various sensor (acceleration transducer, pressure transducer, temperature sensor, voltage and current sensor etc.), power module.
● embedded computer
Embedded computer can adopt multiple technical grade embedded computer system, is equipped with the multi-functional acquisition module of signal and finishes master control function.
● the signal condition module
The signal condition module is mainly finished functions such as the amplification, decay, isolation, filtering of sensor output signals such as acceleration, pressure, temperature, voltage, electric current, multiplexed, excitation, compensation.Mainly comprise with the lower part, can select configuration according to concrete technical requirement.
Test the speed, phase locking frequency multiplying, tracking synchronization module
Tracking filter module
Interchange, direct current separate and the low-pass filtering amplification module
Electric charge amplifies and low-pass filtering module
Low-pass filtering, amplification module
The current-voltage conversion module
Amplification module
The thermopair conditioning module
The thermal resistance conditioning module
● sensor
Mainly comprise sensors such as acceleration, pressure, temperature, voltage, electric current, configuration is selected in concrete technical requirement according to numerically-controlled machine.
● power module
Mainly finish the uninterrupted power supply function of a whole set of terminal.
B) software arrangements
Status monitoring and fault pre-service terminal software comprise signals collecting functional software module, NC communication function software module, status data and fault preprocessing function software module, four parts of telecommunication module.Major function comprises:
System parameter setting function: parameters such as the program control filtering of signalization conditioning case, gain; Parameters such as triggering mode, sample frequency, sampling length are set; Type of alarm, alarm threshold are set and the deposit parameter of reporting to the police; Various data storing paths, holding time are set at interval; Equipment status parameters such as component of machine characteristic parameter are set.
Kinematic parameter monitoring function: monitor each rotation axis rotating speed, axial translation, vibratory output
The power parameter monitoring function: monitor each electric moter voltage, current signal, and synthetic power signal
Pressure parameter monitoring function: monitor each hydraulic unit pressure parameter
Temperature parameter monitoring function: monitoring each point temperature sensor output signal
Operation trend monitoring function: monitoring each point vibratory output
Spectrum monitoring function: monitoring vibration waveform, peak-to-peak value, frequency spectrum and spectrum value list
Data are memory function regularly: when equipment normally moved, per 5 minutes clockwise data buffer area of system were preserved a vibration signal, vibration performance value of preservation in per 5 seconds.
Data warning memory function: when equipment sound and light alarm occurs when unusual and vibratory output and technology amount are stored into respectively in the alert data storehouse of analytical engine.System can each data of 5 minutes of store alarms front and back.
Rise and shut down monitoring function: when device power-up or shutdown, use.Sampling deposit mode is divided into decides the deposit of rotating speed interval sampling, fixed time interval sampling deposit and manually sampling deposit.
NC/PLC information monitoring function: utilize intelligence interfaces such as RS232 to obtain control information and failure code
The fault preprocessing function: utilize various monitoring informations, combining with digital control system failure code dictionary, whether comprehensive judgment device state is normal, as incipient fault or true fault occur, forms status data and failure code packet.
Remote communicating function: carry out net connection with the remote fault diagnosis center, and transferring status data and failure code packet, also can accept the instruction of remote fault diagnosis center, carry out the terminal inner paramter configuration and wait other work.
2) remote fault diagnosis center
A) hardware configuration
Remote fault diagnosis center hardware comprises status data and failure information database server, remote diagnosis server, data communication server compositions such as (comprising fire wall).
Can select configuration by concrete technical requirement.
B) software arrangements
Remote diagnostic center software mainly by obtaining status data and the fault data bag that NC machine tool state monitoring and fault pre-service terminal are beamed back, carries out fault analysis and judgement, and the solution of offering suggestions, guide maintenance work.This software comprises database management function, intelligent expert system diagnostic function, remote collaboration function, remote communicating function four parts.
● database management function
Database management function mainly is a Relational database management function of finishing remote diagnostic center software, comprises retrieval, ordering, editor etc., possesses the data-base content supplementary functions of self study simultaneously.
● the intelligent expert system diagnostic function
The intelligent expert system diagnostic function mainly is after receiving the status data and fault data bag that NC machine tool state monitoring and fault pre-service terminal beam back, according to digital control system fault dictionary and mechanical fault dictionary of information, utilize expert knowledge library and intelligent analysis system to carry out the resultant fault location of control system, electric and mechanical part and analyze.
The resultant fault location and the analysis of control system and electric part
The resultant fault of control system and electric part location is primarily aimed at NC and PLC send in status data that NC machine tool state monitoring and fault pre-service terminal beam back and the fault data bag numerically-controlled machine control system and electric state information, failure code with analyzing, and power signal information, hydraulic unit feedback signal information and temperature information analyze, and fault type mainly comprises the following aspects:
The serial communication problem;
Mechanical part resultant fault location and analysis
Utilize vibration signal,, use traditional time domain or frequency-domain analysis method in conjunction with other sensor feedback signals, and in conjunction with modern wavelet analysis method, the steady and non-stationary signal in the main analytical equipment fault diagnosis.By comprehensive use, can effectively capture the failure message that comprises in the vibration signal to them.These functions comprise:
Cluster analysis
Residual oscillation after estimation increases the weight of
Intelligence automatic diagnosis module has self-learning function, and along with further use at the scene, system will improve the accuracy rate of Fault Identification.
The remote collaboration function
The remote collaboration function at first is after above fault diagnosis, location and analytical work are finished, and the remote fault diagnosis center will be diagnostic result and the long-range numerically-controlled machine applying unit that feeds back to of suggestion method for maintaining; Simultaneously also can be when the intelligent expert diagnostic system can't carry out localization of fault at present, the long-range contact expert that be correlated with, formation " the virtual consultation of doctors " pattern is further carried out fault diagnosis, location and analytical work.
Remote communicating function
Remote communicating function mainly is to utilize INTERNET or wireless network, realizes remote fault diagnosis center and NC machine tool state monitoring and fault pre-service terminal, perhaps the net connection function at other dependent diagnostic center.
Claims (3)
1. novel numerically controlled machine remote condition monitoring and fault diagnosis system implementation method, it is characterized in that, utilize remote modern observation and control technology and Analysis on Fault Diagnosis technology, the characteristics of combining with digital control conditions of machine tool monitoring and fault diagnosis, set up one novel based on wired and numerically controlled machine remote condition monitoring and fault diagnosis system implementation method wireless internet network.Mainly be divided into following two parts based on wired and numerically controlled machine remote condition monitoring and fault diagnosis system wireless internet network: the one, NC machine tool state monitoring and fault pre-service terminal, mainly finish the status monitoring and the failure message preprocessing function at numerically-controlled machine scene, be placed on the numerically-controlled machine; The 2nd, the remote fault diagnosis center mainly realizes being placed in the function of expert system fault analysis and diagnosis on the server of numerically-controlled machine producer.
2. NC machine tool state monitoring described in claim 1 and fault pre-service terminal, it is characterized in that, the core component that is used for status monitoring and fault diagnosis is NC machine tool state monitoring and fault pre-service terminal, this terminal is by electric adaptable interface (comprising the signal condition part) and vibration transducer (acceleration transducer), pressure transducer, temperature sensor, voltage is connected with current sensor etc., these sensors are directly installed on the main position of numerically-controlled machine (as main shaft/feed shaft and bearing, motor, hydraulic transmission part, transmission cases etc.), direct-on-line detects the key message at these positions; Simultaneously by the digital control system intelligent communication interface, obtain the failure code of various electric state data of digital control system and appearance, comprehensively carry out the pre-service of various data, and utilize state analysis and fault handling technology, form status data and fault data bag, and break down or incipient fault in, utilize network that this packet is sent to the remote fault diagnosis center of numerically-controlled machine manufacturer, finish the function of remote condition monitoring and fault diagnosis terminal.
3. the remote fault diagnosis center described in claim 1, it is characterized in that, this central platform is by the status data and the failure code bag of INTERNET or each NC machine tool state monitoring terminal of the online acquisition of wireless network, the working data base of every numerically-controlled machine is gone in unloading, utilize expert system fault diagnosis storehouse simultaneously, carry out fault analysis, and can adopt the mode of virtual expert's remote medical consultation with specialists, the failure judgement content, and processing suggestion or method are provided, instruct numerically-controlled machine applying unit Technical Maintenance Staff or our factory's after-sales service personnel to carry out the maintenance of numerically-controlled machine.
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