CN103884371A - Fault diagnosis device and method based on WIA-PA wireless vibration instrument - Google Patents
Fault diagnosis device and method based on WIA-PA wireless vibration instrument Download PDFInfo
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- CN103884371A CN103884371A CN201210560416.XA CN201210560416A CN103884371A CN 103884371 A CN103884371 A CN 103884371A CN 201210560416 A CN201210560416 A CN 201210560416A CN 103884371 A CN103884371 A CN 103884371A
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Abstract
The invention relates to a fault diagnosis device based on a WIA-PA wireless vibration instrument. An industrial Ethernet is connected with an upper computer, a server and a wireless gateway; and the wireless gateway is in wireless communication with the wireless vibration instrument arranged on industrial equipment. The method comprises the following steps: the wireless vibration instrument is connected to a WIA wireless network; if the wireless vibration instrument is used for the first time, the upper computer sets diagnosis process parameters and sends down the diagnosis process parameters, and the wireless vibration instrument keeps the diagnosis process parameters; if the wireless vibration instrument is not used for the first time, the wireless vibration instrument judges whether run time reaches a data acquisition refresh period of itself; if the run time does not reach the data acquisition refresh period, the diagnosis is terminated; if the run time reaches the data acquisition refresh period, the wireless vibration instrument is started to finish the operation; the upper computer receives the processed data and gives terminating command; and the data is uploaded to a database for fault analysis. The fault diagnosis device and method can meet the low power consumption requirement of the self-powered wireless instrument, and thus the work life of the battery of the instrument is improved.
Description
Technical field
The present invention relates to a kind of method and device of actuating equipment fault diagnosis.Device is carried out fault diagnosis based on vibration, and passes through WIA-PA wireless network transmissions vibration data to host computer, further realizes high level diagnostics.
Background technology
In the modern enterprises such as oil, chemical industry, metallurgy and electric power, the equipment such as blower fan, compressor, pump, motor are all the crucial tools of production, these equipment are carried out to state-detection and fault diagnosis work, and the operation that support equipment is safe and reliable, can obtain huge economic benefit and social benefit.Vibration has destructiveness to the equipment in these work, for example rotor uneven or impact, and the rolling between part and phase mutual friction, the gap producing between part or loosening, what piece surface produced peel off or crackle etc.These vibrations will cause element fault or inefficacy.
The vibration and noise signals that vibration instrument produces by being directly installed on the vibration transducer sensor device of machine surface; identification abnormal vibrations amplitude in conjunction with host computer database Judging fault part and fault type; thereby the parts that maintenance or replacing fault or performance reduce, the loss of avoiding machine halt trouble to cause.For example, instrument is mounted to deoxidation pump, detects in real time the vibration of deoxidation pump, analyze vibration signal find the potential fault of pump as uneven, misalign, bearing fault etc., realize the maintenance based on state.
Vibration diagnosis can be found the parts that fault or performance reduce in advance, changes in advance or maintenance, reduces maintenance cost and avoids shutting down suddenly the economic loss causing.Tradition wired instrument installation wiring complexity, cable is purchased, laying and maintenance cost high.Wireless instrument based on WIA-PA network can well meet the demand of system monitoring.Intelligent wireless network WIA (Wireless Networks for Industrial Automation) is based on short-distance wireless communication IEEE802.15.4 standard, use free frequency band, solve multipath effect wireless signal reflection, scattering being caused at large-scale apparatus, metallic conduit etc., and the electromagnetic noise that the running of motor, apparatus produces disturbs radio communication, provide highly reliable, real-time radio Communications service.Intelligent wireless network WIA technology is specially adapted to Industry Control and factory automation process control, and is widely used in the fields such as oil, chemical industry, metallurgy, mine.
Summary of the invention
For the deficiencies in the prior art, the invention provides a kind of method and device of actuating equipment fault diagnosis.
The technical scheme that the present invention adopted is for achieving the above object: based on the trouble-shooter of WIA-PA wireless vibration instrument, Industrial Ethernet is connected with host computer, server, radio network gateway, and radio network gateway carries out radio communication with being arranged on for the wireless vibration instrument on Diagnosing System for Oil Pump.
Described equipment comprises pump, motor, compressor.
Described wireless vibration instrument comprises: microcontroller is connected with reset circuit, clock circuit, memory circuitry, A/D change-over circuit, radio receiving transmitting module; Vibration transducer is connected with the input end of signal processing circuit, and the output terminal of signal processing circuit is connected with the analog input end of A/D change-over circuit.
Based on the method for diagnosing faults of WIA-PA wireless vibration instrument, comprise the following steps:
Gateway search wireless vibration instrument, wireless vibration instrument enters WIA wireless network;
If wireless vibration instrument is first use, host computer is set diagnostic procedure parameter and is issued to this instrument, and this instrument is preserved diagnostic procedure parameter; If not first use, wireless vibration instrument judges the collecting and refreshing data cycle that whether reaches self working time; Do not reach and finish this diagnosis; Reach and start wireless vibration instrument and complete single treatment operation;
Host computer receives wireless vibration instrument data after treatment by Industrial Ethernet, and issues the finish command to wireless vibration instrument; Then data upload to Fault Diagnosis Database is used for to fault analysis, realizes the fault diagnosis of wireless vibration instrument.
Described diagnostic procedure parameter comprises instrument refresh rate, instrumentation pattern, equipment under test fundamental frequency, fault analysis frequency spectrum frequency, data sampling frequency, data sampling length.
The list processing function of described wireless vibration instrument comprises the following steps:
The data sampling frequency that microcontroller basis in wireless vibration instrument is written into and data sampling length are converted to sensor feedback data by the voltage signal of the sensor that in instrument, A/D change-over circuit receives and carry out the judgement of data scaling and sensor states:
Data scaling is specially sensor feedback data is converted to vibration acceleration signal;
The judgement of sensor states is specially: judge that according to sensor feedback data whether sensor is in normal condition; As extremely, do not start instrumentation; If normal, adopt Fourier transformation method that vibration data is converted into frequency spectrum;
Wireless vibration instrument is sent and is once gathered operation result by radio receiving transmitting module request WIA wireless network; After data transmission completes, the processing of wireless vibration instrument finishes and enters dormant state.
Described employing Fourier transformation method is converted into frequency spectrum data by vibration data and is specially: vibration acceleration signal is converted to the vibration amplitude of time domain, and applies Fast Fourier Transform (FFT) and obtain the frequency spectrum of frequency domain.
Described collection operation result involving vibrations amplitude data and frequency spectrum.
The described fault diagnosis result that obtains comprises the following steps:
Gather vibration trend figure according to the vibration amplitude data in each collecting and refreshing data cycle, determined whether abnormal vibrations according to vibration threshold; If exceed threshold value, this abnormal data input fault diagnostic data base is obtained to failure cause, obtain trouble spot by the table number of instrument.
The present invention has following beneficial effect and advantage:
1. whole application of installation detects in equipment health status, low cost, high efficiency raising parts maintenance cost and efficiency.
2. wireless vibration instrument can intelligence realize the local main power consumption chip power control of instrument, the control of wireless module power supply and probe power control function, and then solves self-power wireless instrument low-power consumption demand, to improve instrument battery service life.
Brief description of the drawings
Fig. 1 trouble-shooter system architecture diagram of the present invention;
Fig. 2 realizes the wireless vibration instrument networking schematic diagram of this device;
Fig. 3 realizes the wireless vibration appliance circuit structured flowchart of this device;
Fig. 4 realizes the wireless vibration instrumentation FB(flow block) of this device;
Fig. 5 trouble-shooter working-flow of the present invention block diagram.
Embodiment
Below in conjunction with drawings and Examples, the present invention is described in further detail.
A kind of method for diagnosing faults and device based on WIA-PA wireless vibration instrument, comprise and be directly installed on the vibration transducer of machine surface for sense vibration signal, carry out the controller of vibration signals collecting and processing, be connected to the radio receiving transmitting module of WIA-PA wireless network, carry the host computer of senior Fault Identification and diagnostic method.
The invention provides a kind of method for diagnosing faults and device, the vibration instrument based on WIA-PA wireless network is realized diagnostic data mining for vehicles and processing, and diagnostic monitoring upper computer software is realized the fault diagnosis based on data.The present invention is for monitoring the health status of commercial unit work, and the parts that identification fault and performance reduce also keep in repair or change before fault occurs.
Fig. 1 comprises the system topological figure that monitors the wireless vibration instrument 19 of fault and the method for diagnosing faults of monitoring diagnosis system 11 and device.Wireless vibration instrument is connected to monitored equipment 23,24,25 by sensor interface 20,21,22, adopts acceleration transducer sense vibrations signal.Monitored equipment can be the equipment such as pump, motor, compressor.Monitoring diagnosis system 11 comprises industrial computer, operating system and fault analysis application software, data storing software etc., by the vibration data storage by sending here on WIA radio network gateway 15, computing analysis, and then identification fault components and parts and fault level.Backstage WIA server 12, Industrial Ethernet 14, WIA radio network gateway 15, wireless vibration instrument 19 forms WIA wireless network.Backstage WIA server 12 comprises computing machine, operating system and user application software, file journalization etc.Be used for the configuration to equipment, the control to equipment under network, detect the function such as storage of analysis of information collection, data.User is issued to the instrument in WIA wireless network by WIA server user end by corresponding information command.WIA radio network gateway connects into Industrial Ethernet 14 by network interface 13, and then communicates by letter with backstage WIA server 12 and monitoring vibrational system 11.A gateway can connect multiple wireless vibration instrument by wireless receiving and dispatching signal 16, is convenient to realize factory's multicomputer monitoring of tools networking application.For example, wireless vibration instrument 17,18,19 in figure etc. can realize the health status monitoring of deoxidation pump group motor and axle, and will on the vibration data of test point separately, deliver to WIA radio network gateway 15 by access WIA wireless network, gateway is uploaded to monitoring and diagnosis system 11 by data by Industrial Ethernet again, completes whole supervisory system function.
Fig. 2 is the wireless vibration instrument networking schematic diagram of realizing this device.The deoxidation pumping set in for example certain cogeneration plant workshop, vibration transducer 31 is directly installed on equipment under test 25 control points, as the X of motor to and Y-direction.Wireless vibration instrument 19 is connected to vibration transducer by sensor interface 30, the electric signal that sensor interface 30 comprises probe power and sense vibration.Wireless vibration instrument 19 provides working sensor power supply, and the electric signal of receiving sensor feedback.Instrument and sensor are installed nearby, in case noise and loss in stop signal transmitting procedure.Signal is after the signal processing module 28 and data processing module 27 processing of wireless vibration instrument this locality, be uploaded to the WIA radio network gateway in deoxidation pumping set workshop via WIA network 29, be connected to background server and diagnosis host computer in pulpit by network interface again, realize the health status monitoring to unit, simplify field power supply and signal transmission wiring, cost-saving.
Fig. 3 is the circuit structure block diagram of realizing the wireless vibration instrument 19 of this device.By microcontroller 32, vibration transducer 31, signal processing circuit 37, A/D change-over circuit 36, radio receiving transmitting module 39, power circuit 38, wireless module power supply 41, probe power 40 compositions such as circuit module such as grade.Probe power 40 modules of instrument, for vibration transducer 31 provides working power, are designed with power control function to guarantee instrument low-power consumption work in module.In instrument, signal processing circuit 37 realizes the functions such as signals collecting, hardware filtering and operation amplifier, so that signal can adapt to the input demand of A/D change-over circuit 36.A/D change-over circuit 36 is realized simulating signal to digital signal conversion and measuring ability, and transformation result is through the number bus transmission between microcontroller 32 and A/D change-over circuit 36.Microcontroller 32 completes vibration amplitude computing, and calculates vibration signal frequency spectrum data according to known sample frequency and sampling length.Microcontroller 32 peripheral circuits comprise reset circuit 33, clock circuit 34, memory circuitry 35 and other microcontroller mini system circuit.The storer that memory circuitry 35 comprises buffer memory intermediate data storage device and loading instrument list procedure and configuration parameter.Microcontroller 32 is according to the collection of pre-configured parameter log-on data, computing and transfer data to WIA wireless network by peripheral radio receiving transmitting module 39.Radio receiving transmitting module 39 power supplys are provided by instrument equally, and instrument design has power control function to realize wireless module low-power consumption work according to WIA network state., in work, all issue by WIA wireless network by command information and instrument arrangement information, microcontroller 32 receives and according to proprietary protocol resolve command and the local allocation list of renewal instrument, user is configured and preserved meanwhile.
Fig. 4 is the wireless vibration instrumentation FB(flow block) that realizes this device.In wireless vibration instrument 19, be designed with power management function, start 45 according to corresponding configuration (instrumentation pattern is battery saving mode or normal mode) or user instruction information control instrument program.After instrument starts, need to carry out instrument initialization 46, comprise and load the start-up routine of microcontroller 32 and be written into configuration parameter information, comprise instrumented data frequency acquisition, data acquisition length, Refresh Data rate, analyzed equipment fundamental frequency, analyze frequency, instrumentation pattern, identification instrument current operation instruction etc.After initialization completes, in instrument, microcontroller gathers 47 processes according to the sample frequency and the length log-on data that are written into, and gatherer process comprises data scaling and sensor states judgement, and sensor states judgement is exactly to judge that whether sensor bias voltage is normal; And if then sensor is in place or extremely to determine whether log-on data to process 48 processes, not log-on data processing.Data scaling is, according to the A/D converter in instrument, received voltage signal is converted to corresponding vibration acceleration signal; Judge that whether sensor is in place and whether power supply is normal, as extremely, do not start instrumentation.Data processing 48 is mainly that vibration data is converted into frequency spectrum data, comprise digital filtering, FFT(Fast Fourier Transform (FFT)), the data operation Processing Algorithm such as wavelet transformation, first carry out FFT conversion according to analyzing fundamental frequency and frequency and sample frequency, sampling length, transformation results completes data compression and then by WIA Internet Transmission through wavelet transformation; Be specially according to sample frequency and sampling length pick-up transducers data, the time domain data array obtaining is according to calculating vibration amplitude; And apply Fast Fourier Transform (FFT) FFT and obtain meeting the frequency spectrum of equipment under test fundamental frequency and fault analysis frequency spectrum frequency: application Fast Fourier Transform (FFT) completes the conversion of time domain to frequency domain data, and then according to frequency spectrum failure judgement reason; Wherein, the setting value of sample frequency is at least three times of equipment under test rotating speed, and fundamental frequency is equipment under test rotating speed, and fault analysis frequency spectrum frequency needs professional may existence form to set according to device type and fault.
Complete after processing procedure, instrument is started and is connected WIA wireless network process 49 by radio receiving transmitting module 39, and request network sends and once gathers operation result.Data transmission 50 is followed WIA network data transmission proprietary protocol, for improving data transmission credibility, in host-host protocol, design CRC check and retransmission mechanism step by step, and design corresponding warning and log information at user api, to facilitate whole diagnostic system to safeguard.After completing data transmission and handshaking information and completing alternately, instrument program is hung up, and enters 51 processes of end.Now, whole instrument enters dormant state to save power consumption except function is controlled in management, and program is waited for next time and being started.
Fig. 5 is trouble-shooter working-flow block diagram of the present invention.Start 53 from starting WIA gateway control end software, first complete WIA network configuration 54, then network 55 according to the wireless ID search of instrument wireless vibration instrument, instrument and radio network gateway complete handshake communication.(user refers to the slip-stick artist who uses this diagnostic system to user; According to whether being to install and use for the first time this diagnostic system to judge whether modification process parameter) first judge whether that diagnostic procedure parameter needs amendment, as need amendment, carry out 56 and issue parameter configuration and preserve parameter configuration 57; If do not needed amendment, judge whether to meet the diagnostic data mining for vehicles refresh cycle, do not meet and directly finish 60 these operations, satisfied start wireless vibration instrument 58 and carry out single job.Host computer receiving instrument passback data after complete operation, and issue the order of end wireless vibration instrumentation.After completing by data upload to fault diagnosis software database 59, use for fault diagnosis and while checking historical data.Uploading data comprises vibration amplitude data, and frequency spectrum data; Fault diagnosis software database 59 gathers vibration trend figure according to the vibration amplitude data of per refresh cycle, vibration amplitude when this figure shows normal operation of sensor state; Determine whether abnormal vibrations according to vibration threshold; According to the rumble spectrum data input fault diagnostic data base of per refresh cycle, this database is made up of the fault data of sensor, comprises frequency spectrum data and its corresponding failure cause, and therefore input spectrum data just can obtain failure cause; Host computer just can obtain trouble spot by the table number of wireless vibration instrument.
Claims (9)
1. the trouble-shooter based on WIA-PA wireless vibration instrument, it is characterized in that: Industrial Ethernet (14) is connected with host computer (11), server (12), radio network gateway (15), radio network gateway (15) carries out radio communication with being arranged on for the wireless vibration instrument (19) on Diagnosing System for Oil Pump.
2. method for diagnosing faults and the device based on WIA-PA wireless vibration instrument according to claim 1, is characterized in that: described equipment comprises pump, motor, compressor.
3. method for diagnosing faults and the device based on WIA-PA wireless vibration instrument according to claim 1, is characterized in that: described wireless vibration instrument (19) comprising: microcontroller (32) is connected with reset circuit (33), clock circuit (34), memory circuitry (35), A/D change-over circuit (36), radio receiving transmitting module (39); Vibration transducer (31) is connected with the input end of signal processing circuit (37), and the output terminal of signal processing circuit (37) is connected with the analog input end of A/D change-over circuit (36).
4. the method for diagnosing faults based on WIA-PA wireless vibration instrument, is characterized in that comprising the following steps:
Gateway search wireless vibration instrument (19), wireless vibration instrument (19) enters WIA wireless network;
If wireless vibration instrument (19) is first use, host computer (11) is set diagnostic procedure parameter and is issued to this instrument, and this instrument is preserved diagnostic procedure parameter; If not first use, wireless vibration instrument (19) judges the collecting and refreshing data cycle that whether reaches self working time; Do not reach and finish this diagnosis; Reach and start wireless vibration instrument (19) and complete single treatment operation;
Host computer (11) receives wireless vibration instrument (19) data after treatment by Industrial Ethernet (14), and issues the finish command to wireless vibration instrument (19); Then data upload to Fault Diagnosis Database is used for to fault analysis, realizes the fault diagnosis of wireless vibration instrument.
5. the method for diagnosing faults based on WIA-PA wireless vibration instrument according to claim 4, is characterized in that: described diagnostic procedure parameter comprises instrument refresh rate, instrumentation pattern, equipment under test fundamental frequency, fault analysis frequency spectrum frequency, data sampling frequency, data sampling length.
6. the method for diagnosing faults based on WIA-PA wireless vibration instrument according to claim 4, is characterized in that: described wireless vibration instrument (19) is processed operation and comprised the following steps:
The data sampling frequency that microcontroller (32) basis in wireless vibration instrument (19) is written into and data sampling length are converted to sensor feedback data by the voltage signal of the sensor that in instrument, A/D change-over circuit (36) receives and carry out the judgement of data scaling and sensor states:
Data scaling is specially sensor feedback data is converted to vibration acceleration signal;
The judgement of sensor states is specially: judge that according to sensor feedback data whether sensor is in normal condition; As extremely, do not start instrumentation; If normal, adopt Fourier transformation method that vibration data is converted into frequency spectrum;
Wireless vibration instrument (19) is sent and is once gathered operation result by radio receiving transmitting module (39) request WIA wireless network; After data transmission completes, wireless vibration instrument (19) processing finishes and enters dormant state.
7. the method for diagnosing faults based on WIA-PA wireless vibration instrument according to claim 6, it is characterized in that: described employing Fourier transformation method is converted into frequency spectrum data by vibration data and is specially: vibration acceleration signal is converted to the vibration amplitude of time domain, and applies Fast Fourier Transform (FFT) and obtain the frequency spectrum of frequency domain.
8. the method for diagnosing faults based on WIA-PA wireless vibration instrument according to claim 6, is characterized in that: described collection operation result involving vibrations amplitude data and frequency spectrum.
9. the method for diagnosing faults based on WIA-PA wireless vibration instrument according to claim 4, is characterized in that: described in obtain fault diagnosis result and comprise the following steps:
Gather vibration trend figure according to the vibration amplitude data in each collecting and refreshing data cycle, determined whether abnormal vibrations according to vibration threshold; If exceed threshold value, this abnormal data input fault diagnostic data base is obtained to failure cause, obtain trouble spot by the table number of instrument.
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| CN108645619A (en) * | 2018-07-25 | 2018-10-12 | 深圳大图科创技术开发有限公司 | Mechanical bearing vibrates intelligent monitor system |
| CN108871434A (en) * | 2018-05-30 | 2018-11-23 | 北京必创科技股份有限公司 | A kind of on-line monitoring system and method for slewing |
| CN109163796A (en) * | 2018-09-10 | 2019-01-08 | 广州小楠科技有限公司 | Bearing in rotating machinery vibration data intelligence is capable of real-time acquisition and analysis system |
| CN110207810A (en) * | 2018-02-28 | 2019-09-06 | 常州路航轨道交通科技有限公司 | Axle box vibration detecting system |
| CN113272659A (en) * | 2018-12-07 | 2021-08-17 | Itt制造企业有限责任公司 | Embedded system for vibration detection and analysis |
| CN114698072A (en) * | 2022-03-21 | 2022-07-01 | 沈阳中科奥维科技股份有限公司 | Low-power-consumption circuit of WIA-PA wireless vibration transmitter and control method |
| CN114719958A (en) * | 2022-03-21 | 2022-07-08 | 沈阳中科奥维科技股份有限公司 | Vibration monitoring system and method based on WIA-PA and 4G double wireless technology |
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| TWI578134B (en) * | 2015-07-24 | 2017-04-11 | 國立勤益科技大學 | Linear slide bearing monitoring system |
| CN107121943B (en) * | 2016-02-24 | 2020-07-28 | 西门子公司 | Method and device for obtaining health prediction information of intelligent instrument |
| CN107121943A (en) * | 2016-02-24 | 2017-09-01 | 西门子公司 | A kind of method and apparatus for being used to obtain the health forecast information of intelligence instrument |
| CN110207810A (en) * | 2018-02-28 | 2019-09-06 | 常州路航轨道交通科技有限公司 | Axle box vibration detecting system |
| CN110207810B (en) * | 2018-02-28 | 2021-11-30 | 常州路航轨道交通科技有限公司 | Axle box vibration detection system |
| CN108871434A (en) * | 2018-05-30 | 2018-11-23 | 北京必创科技股份有限公司 | A kind of on-line monitoring system and method for slewing |
| CN108871434B (en) * | 2018-05-30 | 2024-05-31 | 北京必创科技股份有限公司 | Online monitoring system and method for rotating equipment |
| CN108645619A (en) * | 2018-07-25 | 2018-10-12 | 深圳大图科创技术开发有限公司 | Mechanical bearing vibrates intelligent monitor system |
| CN108645619B (en) * | 2018-07-25 | 2020-05-12 | 浙江福库工业科技有限公司 | Intelligent monitoring system for vibration of mechanical bearing |
| CN109163796A (en) * | 2018-09-10 | 2019-01-08 | 广州小楠科技有限公司 | Bearing in rotating machinery vibration data intelligence is capable of real-time acquisition and analysis system |
| CN113272659A (en) * | 2018-12-07 | 2021-08-17 | Itt制造企业有限责任公司 | Embedded system for vibration detection and analysis |
| CN114698072A (en) * | 2022-03-21 | 2022-07-01 | 沈阳中科奥维科技股份有限公司 | Low-power-consumption circuit of WIA-PA wireless vibration transmitter and control method |
| CN114719958A (en) * | 2022-03-21 | 2022-07-08 | 沈阳中科奥维科技股份有限公司 | Vibration monitoring system and method based on WIA-PA and 4G double wireless technology |
| CN114698072B (en) * | 2022-03-21 | 2024-04-26 | 沈阳中科奥维科技股份有限公司 | Low-power-consumption circuit of WIA-PA wireless vibration transmitter and control method |
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