CN104035433A - Remote precise diagnosis and maintenance system and method of industrial devices - Google Patents
Remote precise diagnosis and maintenance system and method of industrial devices Download PDFInfo
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- CN104035433A CN104035433A CN201410238751.7A CN201410238751A CN104035433A CN 104035433 A CN104035433 A CN 104035433A CN 201410238751 A CN201410238751 A CN 201410238751A CN 104035433 A CN104035433 A CN 104035433A
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Abstract
The invention discloses a remote precise diagnosis and maintenance system and method of industrial devices. According to the remote precise diagnosis and maintenance system, the fault diagnosis and maintenance on the industrial devices is implemented through comprehensive measures in a three-dimensional crossing mode, integration treatment is performed on diagnosis ways of the various industrial devices, remote consultation of experts can be implemented, remote diagnosis results can be obtained, and accordingly the operation maintenance cost of the industrial devices of factories can be reduced and the production safety can be improved.
Description
Technical field
The present invention relates to commercial unit field, particularly a kind of long-range accurate diagnosis of commercial unit and maintenance system and method.
Background technology
To a certain factory with the commercial unit of number of different types, while managing such as power plant, relate to a lot of because have of cost: starting material, equipment control maintenance, tax and wage.Tax and wage are wherein fixed, and raw-material cost also more restricted by external environment condition, wayward.Therefore,, in order to reduce costs, need to carry out effective management maintenance to the commercial unit in factory.
At present, when the commercial unit of Dui factory is safeguarded, the mode that the mode of employing is " put prevention first, scheduled overhaul is main, interim repairing is auxiliary ".Specifically, factory is according to the new and old situation of commercial unit, set 3 years to 5 years and schedule to last, whole commercial units in factory are carried out to an overhaul, whole commercial units are stopped transport, disassemble, maintained and return the operation of dress, and specifically do not consider whether certain commercial unit needs repairing, a general overhaul is by a definite date more than two months, need specialized maintenance personnel over hundreds of, all kinds of workmen's summation nearly 1000 people.During twice overhaul, each carried out a light maintenance by 2 years to commercial unit, auxiliary operating devices in Ji Dui factory, such as dress is disassembled, maintains and returned to the most commercial units beyond the Turbo-generator Set in power plant and other large-scale nucleus equipments, generally tens days to two months by a definite date not etc.Meanwhile, factory is when carrying out " scheduled overhaul ", and auxiliary with " repairing temporarily ", the commercial unit that cannot turn round for breaking down is rushed to repair temporarily.
Above-mentionedly thisly the commercial unit of factory is carried out to maintenance mode be widely used in domestic all electric power, the heavy industry enterprises such as metallurgy and petrochemical industry, but, thisly the commercial unit of factory is carried out to maintenance mode also deposit shortcoming both ways: first, apparently, this commercial unit maintenance mode can produce the greatly wasting of resources, because scheduled overhaul is ignored the concrete operation conditions of each concrete commercial unit completely, adopt unified maintenance mode to treat all commercial units in factory, cause personnel, time and all produced economically unnecessary huge input, the second, this commercial unit maintenance mode can cause some commercial units wherein to accelerate inefficacy and aging, can not guarantee during twice overhaul, and each commercial unit in factory is reliable even running all, also needs auxiliary to rush to repair temporarily.
Take China generating factory is example, and current Chinese Wu great electricity power group, devotes the expense of equipment repair and maintenance every year all on tens billion of units.Yet, these great numbers pay the return that can not obtain application.This be because; the process equipment system of generating factory is comparatively complicated; the feature such as the commercial unit kind that has is many, running environment is poor, the operational factor of working medium operating mode is changeable; with " putting prevention first and scheduled overhaul ", take the commercial unit maintenance mode of thought as the leading factor and can not effectively avoid the generation of the accidents such as hang-up; more can not adapt to current production development demand; make on the contrary commercial unit for a long time in fault repairing; repaired fault; in the middle of a vicious cycle of repairing again after fault, operation expense and Safety Risk in Production have unrestrictedly been increased.
Summary of the invention
In view of this, the embodiment of the present invention provides a kind of long-range accurate diagnosis and maintenance system of commercial unit, and this system can reduce the commercial unit operation expense of factory and improve production security.
The embodiment of the present invention also provides a kind of long-range accurate diagnosis and maintaining method of commercial unit, and the method can reduce the commercial unit operation expense of factory and improve production security.
According to above-mentioned purpose, the present invention is achieved in that
Long-range accurate diagnosis and the maintenance system of commercial unit, comprising: commercial unit remote diagnosis database, diagnostic model database, diagnostic device, expert terminals and plant terminal, wherein,
Equipment account terminal, for recording commercial unit information, accepts calling of plant terminal, and commercial unit information is offered to plant terminal;
Plant terminal, for according to the commercial unit information of calling from equipment account terminal, determines the commercial unit that will diagnose, controls diagnostic device commercial unit is diagnosed; According to the commercial unit diagnostic result or the maintenance information that receive from commercial unit remote diagnosis database, or receive the maintenance information from diagnostic model database, offer maintainer, supply maintainer with reference to commercial unit diagnostic result, or indication maintainer safeguard to commercial unit according to maintenance information;
Diagnostic device, under the control of plant terminal, diagnostic device is diagnosed commercial unit, and the commercial unit diagnostic data obtaining is sent to commercial unit remote diagnosis database;
Commercial unit remote diagnosis database, for storing the commercial unit diagnostic result corresponding to commercial unit diagnostic data, determines corresponding commercial unit diagnostic result according to the commercial unit diagnostic data receiving from diagnostic device, sends to plant terminal; Or the commercial unit diagnostic data receiving from diagnostic device is sent to diagnostic model database or sends to expert terminals, the maintenance information receiving from expert terminals is sent to plant terminal;
Diagnostic model database, for storing the maintenance information of corresponding commercial unit diagnostic data, receives after the commercial unit diagnostic data of commercial unit remote diagnosis database transmission, obtains corresponding maintenance information, sends to plant terminal;
Expert terminals, the commercial unit diagnostic data sending for receiving commercial unit remote diagnosis database, carries out, after remote diagnosis, being maintained information, sends to plant terminal.
Described diagnostic device is a plurality of, adopts different interfaces to connect respectively from commercial unit remote diagnosis database, carries out the diagnosis of corresponding different commercial units.
Described diagnostic device comprises: one or more in vibration monitoring instrument, infrared thermography, ultrasonic detection equipment, current spectrum instrument, fluid ferrograph analyzer, fluid laser particle degree calculating instrument, laser velocity gauge and spot dynamic balance instrument.
Described commercial unit information comprises: one or more in commercial unit kind, number of units, model and structure and parameters;
Described equipment account terminal, also for when storing described commercial unit information, according to the operating area storage of commercial unit.
Described commercial unit remote diagnosis database, also, for being non-when abnormal when definite corresponding commercial unit diagnostic result, directly sends to plant terminal; When definite corresponding commercial unit diagnostic result is while being abnormal, the commercial unit diagnostic data receiving from diagnostic device is sent to diagnostic model database or sends to expert terminals.
Long-range accurate diagnosis and the maintaining method of commercial unit, the method comprises:
The storage of commercial unit remote diagnosis database is corresponding to the commercial unit diagnostic result of commercial unit diagnostic data;
During commercial unit diagnostic data that commercial unit remote diagnosis database receives from diagnostic device, determine corresponding commercial unit diagnostic result, send to plant terminal.
During the commercial unit diagnostic result of described definite correspondence, if this commercial unit diagnostic result is abnormal, the method also comprises:
The commercial unit diagnostic data receiving from diagnostic device is sent to diagnostic model database or sends to expert terminals, the maintenance information receiving from expert terminals is sent to plant terminal;
Or by diagnostic model database, stored the maintenance information of corresponding commercial unit diagnostic data, receive after the commercial unit diagnostic data of commercial unit remote diagnosis database transmission, obtain corresponding maintenance information, send to plant terminal.
Described diagnostic device is different and different according to the type of the commercial unit of diagnosis, comprising: one or more in vibration monitoring instrument, infrared thermography, ultrasonic detection equipment, current spectrum instrument, fluid ferrograph analyzer, fluid laser particle degree calculating instrument, laser velocity gauge and spot dynamic balance instrument.
The process that obtains of described commercial unit diagnostic data is:
Record commercial unit information;
According to the commercial unit information of calling, determine the commercial unit that will diagnose, control diagnostic device commercial unit is diagnosed, obtain described commercial unit diagnostic data.
Commercial unit information comprises: one or more in commercial unit kind, number of units, model and structure and parameters.
As can be seen from the above scheme, the long-range accurate diagnosis of the commercial unit that the embodiment of the present invention provides and maintenance system and method are to the fault diagnosis of commercial unit and safeguard that the crossings on different level of employing comprehensive means realizes, the diagnostic mode of various commercial units is carried out to integrated processing, and can realize expert's remote medical consultation with specialists and obtain remote diagnosis result.Therefore, can reduce the commercial unit operation expense of factory and improve production security.
Accompanying drawing explanation
Fig. 1 is the existing damage curve figure safeguarding in theory;
Fig. 2 is the commercial unit damage curve figure of actual approval;
Long-range accurate diagnosis and the maintenance system structural representation of the commercial unit that Fig. 3 provides for the embodiment of the present invention;
Long-range accurate diagnosis and the maintaining method process flow diagram of the commercial unit that Fig. 4 provides for the embodiment of the present invention.
Embodiment
For making object of the present invention, technical scheme and advantage clearer, referring to the accompanying drawing embodiment that develops simultaneously, the present invention is described in further detail.
Adopt " put prevention first, scheduled overhaul is main, interim repairing is auxiliary " mode to safeguard the commercial unit of factory, make operation expense reason large and that increased Safety Risk in Production mainly contain following 3 points:
The first point, based on theoretical mistake.
Commercial unit before the seventies in last century is safeguarded in theory, think that commercial unit can not break down at initial operation stage, the generation of commercial unit fault is mainly aging the causing that the increase due to tenure of use causes, as shown in Figure 1, Fig. 1 is the existing damage curve figure safeguarding in theory, wherein transverse axis is the time, and the longitudinal axis is fault.
But, after the seventies in last century, this maintenance is theoretical is given negative by a large amount of experiments and data, as shown in Figure 2 six kinds of the commercial unit damage curve of at present educational circles's approval, can find out real commercial unit damage curve and comparing of thinking in theory the seventies, want complicated a lot, and the theoretical curve shown in Fig. 1 can only reflect a kind of situation wherein, wherein transverse axis is the time, and the longitudinal axis is fault.On city-level, the trouble or failure of most industry equipment is all random, with time-independent, and safeguards in some cases the trouble or failure that may accelerate commercial unit.
Therefore, the theory that " scheduled overhaul is main " follows, " commercial unit can not break down in the gas storage that puts into operation, equipment failure be the aging theory causing that the increase due to tenure of use causes " is basic wrong or incomplete.And take the maintenance mode that this theory is that basis is formulated, will cause the waste of ample resources and the very large fault that may accelerate commercial unit.
Second point, technical limitation.
In carrying out the commercial unit maintenance process of factory, some factories have realized that employing " put prevention first, scheduled overhaul is main, interim repairing is auxiliary " mode exists very large defect, but because technical capability is limit, is difficult to improve.Such as generating factory, medium-sized generating factory generally have more than two covers can independent operating genset, thousands of kinds of the commercial units of every cover unit, the operating mode principle of every kind is all different, these thousands of kinds of commercial units exist again mutual restriction and cooperate simultaneously, be difficult to unified planning maintenance mode, if formulate suitable commercial unit way to manage according to every or every kind of commercial unit s own situation, needed technological means and checkout equipment, kind is numerous and diverse, various in style, calculated amount is very big, rely on manual record can not complete unified allocation of resources or integration work.
Further, single commercial unit fault diagnosis mode, there is no Integration Mode effectively, Reng Yi power plant is example, the general use of being only responsible for a kind of or a class checkout equipment of current commercial unit maintainer, such as infrared detection personnel only can grasp the using method of infrared equipment and analyze main points, for other detection meanss such as ultrasonic, vibration or fluid, have little understanding.But for the fault diagnosis of the commercial unit of a certain operation in factory, the multiple detection method of having only had integrated use, could judge targetedly whether have fault, or trouble spot wherein.The favourable turn class commercial unit of take is example, effectively fault diagnosis mode is: diagnostic analysis-judge whether vibration exceeding the standard, infrared analysis-judge whether local overheating phenomenon, ultrasonic-judgement lubricant effect, oil analysis-judgement bearing wear, and current of electric analysis-judgement electrical fault problem, this is a primary fault diagnosis, for more complicated commercial unit or problem, also needs to introduce other more complicated fault diagnosis modes.In practical operation; because commercial unit maintainer only grasps an a kind of or class fault diagnosis mode; the effectively integrate means of shortage to various diagnostic results or information; and coordinate a plurality of commercial unit maintainers concentrate certain commercial unit is judged very difficult; so usually only arrange conventional routine to detect to certain class commercial unit; such as favourable turn commercial unit is only carried out to vibration values size detection; cause the commercial unit of a lot of problems often by mistake, to be thought healthy, the generation that finally causes commercial unit to be shut down.For example, certain water pump vibration does not exceed standard, but bearing lubrication goes wrong, and oil temperature is too high, but fails to pinpoint the problems owing to only it having been carried out to vibration detection, and erroneous judgement industrial device controls, finally causes main shaft locking, burns bearing, causes hang-up.
Thirdly, commercial unit exceptional fault cannot be got rid of in time.
In real work, the failure cause more complicated of commercial unit, this situation is very frequent especially for the commercial unit of large-scale core, such as the Turbo-generator Set of power plant, when there is the problem of unconventional property, still need to a great extent relevant expert's manual analysis to solve.But expert is generally difficult to rush towards power plant in the very first time.If carry out remote diagnosis by network, technical limitation due to communications, also method can not put into practice efficiently, generally by methods such as mails, transmits rumble spectrum picture, or appoints and utilize the peculiar file layout of certain software to transmit by methods such as mails.All there is shortage of data in various degree in these methods, can not actual response site environment and reaction time long, to being combined with requirement between personnel, cannot reach the re-set target of remote diagnosis completely.Substantially, expert can only roughly analyze by data, cannot specifically determine the fault of commercial unit and deal with problems, and even diagnosis is often far from each other with actual cause.
The embodiment of the present invention is safeguarded the commercial unit of factory, is realized, specifically by following three aspects in order to overcome employing " put prevention first, scheduled overhaul is main, interim repairing is auxiliary " mode.
First aspect, long-range accurate diagnosis and the maintenance system of the commercial unit providing by the embodiment of the present invention, commercial unit data by this system based on diagnosed and the maintenance of commercial unit are theoretical, commercial unit is carried out to remote diagnosis and maintenance, thereby fundamentally changing current commercial unit service mode, making up the defect that " plan+interim " safeguarded.
" plan+interim " because scheduled overhaul is not specifically considered the ruuning situation of every commercial unit, carries out regular dismounting maintenance to whole commercial units under safeguarding, caused the significant wastage of manpower, economy and time cost; Secondly, the maintenance theory of commercial unit can prove, some equipment, after detachable maintaining, can promote failure rate on the contrary, and for this commercial unit, schedule maintenance causes on the contrary unnecessary loss and causes non-programmed halt.In addition, schedule maintenance can not guarantee during twice overhaul or light maintenance, and equipment can non-fault even running.During this period, in the face of commercial unit catastrophic failure, need to rush to repair temporarily.And rush to repair in default of planned, need to dispatch extra maintainer and produce extra maintenance cost, delay the normal production run time, can't guarantee that factory resumes production fast, thereby cause larger economic loss. temporarily
Long-range accurate diagnosis and the maintenance system of the commercial unit that the employing embodiment of the present invention provides, commercial unit management maintenance pattern in factory is progressively transitioned into " centered by reliability, carrying out commercial unit accurate diagnosis " by " scheduled overhaul is main, and interim repairing is auxiliary ".After being provided with the long-range accurate diagnosis and maintenance system of the commercial unit that the embodiment of the present invention provides, factory can instruct by the theoretical information arranging in this system in conjunction with the commercial unit data that adopt this system diagnostics to obtain, planning in advance, only for fault commercial unit or have the commercial unit arrangement of incipient fault hidden danger to shut down maintenance and fault is got rid of, without in overhaul or light maintenance, all devices all being dismantled back to dress, greatly saved manpower, time and financial cost, also avoided the situation of " having repaiied bad " due to the commercial unit that theoretical mistake causes simultaneously, improved commercial unit operational reliability.
Second aspect, long-range accurate diagnosis and the maintenance system of the commercial unit that the embodiment of the present invention provides, by the result of the multiple detection means of integrating, contrast diagnostic result and fault model in this system internal database, in monomer commercial unit fault diagnosis, the reason that fault and fault produce be can accurately judge whether, and detailed improvement or maintenance scheme provided.
In actual applications, the long-range accurate diagnosis of the commercial unit that the embodiment of the present invention provides and maintenance system can be got rid of the restriction of maintainer's factor, perfectly integrate multiple commercial unit fault detection technique, make managerial personnel fully understand the every terms of information of commercial unit, effectively check incipient fault, avoid erroneous judgement.Finally, when improving commercial unit reliability, by eliminating interim repairing, reduce the financial cost of equipment control.
The third aspect, when commercial unit occurs that exceptional fault cannot simply solve, the long-range accurate diagnosis of the commercial unit that the embodiment of the present invention provides and maintenance system be by remote diagnosis module, and the on-the-spot firsthand material is real-time transmitted to and in expert terminals, carries out expert diagnosis.No matter be the audio file of rumble spectrum, infrared image or Ultrasonic Detection, the long-range accurate diagnosis of the commercial unit that the embodiment of the present invention provides and maintenance system all can guarantee to transmit undistorted, reduce field condition completely, realize expert diagnosis truly.This function can significantly reduce the time cost of commercial unit maintenance, in a disguised form improves commercial unit working time, lowers the financial cost of commercial unit management maintenance.In addition, in some large-scale group factories, the managerial personnel of group company or general headquarters, the long-range accurate diagnosis of the commercial unit that also can provide by the embodiment of the present invention and the Remote Diagnosis System of maintenance system are checked the commercial unit diagnostic data in factory thousands of miles away, strengthen supervision.
The long-range accurate diagnosis of the commercial unit that the embodiment of the present invention provides and maintenance system are to the fault diagnosis of commercial unit and safeguard that the crossings on different level of employing comprehensive means realizes, the diagnostic mode of various commercial units is carried out to integrated processing, and can realize expert's remote medical consultation with specialists and obtain remote diagnosis result.
Long-range accurate diagnosis and the maintenance system structural representation of the commercial unit that Fig. 3 provides for the embodiment of the present invention, comprising: commercial unit remote diagnosis database, diagnostic model database, diagnostic device, expert terminals and plant terminal, wherein,
Equipment account terminal, for recording commercial unit information, accepts calling of plant terminal, and commercial unit information is offered to plant terminal;
Plant terminal, for according to the commercial unit information of calling from equipment account terminal, determines the commercial unit that will diagnose, controls diagnostic device commercial unit is diagnosed; According to the commercial unit diagnostic result or the maintenance information that receive from commercial unit remote diagnosis database, or receive the maintenance information from diagnostic model database, offer maintainer, supply maintainer with reference to commercial unit diagnostic result, or indication maintainer safeguard to commercial unit according to maintenance information;
Diagnostic device, under the control of plant terminal, diagnostic device is diagnosed commercial unit, and the commercial unit diagnostic data obtaining is sent to commercial unit remote diagnosis database;
Commercial unit remote diagnosis database, for storing the commercial unit diagnostic result corresponding to commercial unit diagnostic data, determines corresponding commercial unit diagnostic result according to the commercial unit diagnostic data receiving from diagnostic device, sends to plant terminal; Or the commercial unit diagnostic data receiving from diagnostic device is sent to diagnostic model database or sends to expert terminals, the maintenance information receiving from expert terminals is sent to plant terminal;
Diagnostic model database, for storing the maintenance information of corresponding commercial unit diagnostic data, receives after the commercial unit diagnostic data of commercial unit remote diagnosis database transmission, obtains corresponding maintenance information, sends to plant terminal;
Expert terminals, can be for a plurality of, and the commercial unit diagnostic data sending for receiving commercial unit remote diagnosis database, carries out, after remote diagnosis, being maintained information, sends to plant terminal.
In this embodiment, due to the difference of commercial unit, the diagnostic device adopting is also different, therefore, diagnostic device has a plurality of, and type is different, adopt different interfaces to connect from commercial unit remote diagnosis database respectively, carry out the diagnosis of corresponding different commercial units.Here, diagnostic device includes but not limited to: one or more in vibration monitoring instrument, infrared thermography, ultrasonic detection equipment, current spectrum instrument, fluid ferrograph analyzer, fluid laser particle degree calculating instrument, laser velocity gauge and spot dynamic balance instrument.
In this embodiment, commercial unit information includes but not limited to: commercial unit kind, number of units, model and structure and parameters, when storage, can be according to the operating area of commercial unit, such as boiler area or turbine area, create commercial unit structure tree, so that management.
In this embodiment, in carrying out the remote diagnosis process of commercial unit, be divided into following three kinds of situations:
The first situation, commercial unit diagnostic result Non Apparent Abnormality;
In this case, commercial unit remote diagnosis database directly feeds back corresponding commercial unit diagnostic result;
The second situation, commercial unit diagnostic result has extremely, but does not need with expert terminals mutual;
In this case, commercial unit remote diagnosis database sends to diagnostic model database by the commercial unit diagnostic data receiving from diagnostic device, this process equipment diagnostic data comprises the key message of this process equipment, such as structure or model etc., by diagnostic model database, analyzed, and according to the corresponding relation arranging, this corresponding relation can be commercial unit fault model, and the maintenance information of finally having integrated commercial unit diagnostic result is sent to plant terminal;
The third situation, commercial unit diagnostic result has extremely, need to be mutual with expert terminals;
The reason that produces this situation is: commercial unit runs into exceptional fault, needs the consultation of doctors of Remote terminal or manual analysis separately, provides suggestion (need to have feedback); Or need to carry out long-range industrial device controls (without there being feedback) by expert terminals.In this case, can utilize internet, by commercial unit remote diagnosis database, the commercial unit diagnostic data receiving from diagnostic device be sent to expert terminals, by expert terminals, be processed, or feedback maintenance information, or do not feed back.In this case, commercial unit diagnostic data has comprised this commercial unit information, is specially account information, historical data and every testing result, and expert terminals is after analysis, and feedback has comprised the maintenance information of analyzing suggestion.
In embodiments of the present invention; factory under commercial unit can set up maintenance group by a plurality of maintainers; this maintenance group carries out fault diagnosis and maintenance by system provided by the invention to commercial unit equipment, whether a certain commercial unit is needed to shut down maintenance and have final resolution power.Maintainer in maintenance group can utilize system provided by the invention, diagnostic result and maintenance information that the different detection meanss of comprehensive analysis obtain, find the diagnostic device that is applicable to commercial unit to diagnose, if it is difficult to run into the fault of commercial unit, can carry out remote diagnosis.
Long-range accurate diagnosis and the maintaining method process flow diagram of the commercial unit that Fig. 4 provides for the embodiment of the present invention, its concrete steps are:
Step 401, commercial unit remote diagnosis database are stored the commercial unit diagnostic result corresponding to commercial unit diagnostic data;
During commercial unit diagnostic data that step 402, commercial unit remote diagnosis database receive from diagnostic device, determine corresponding commercial unit diagnostic result, send to plant terminal.
In the method, when determining corresponding commercial unit diagnostic result, if this commercial unit diagnostic result is abnormal, the method also comprises:
The commercial unit diagnostic data receiving from diagnostic device is sent to diagnostic model database or sends to expert terminals, the maintenance information receiving from expert terminals is sent to plant terminal;
Or by diagnostic model database, stored the maintenance information of corresponding commercial unit diagnostic data, receive after the commercial unit diagnostic data of commercial unit remote diagnosis database transmission, obtain corresponding maintenance information, send to plant terminal.
In the method, described diagnostic device is different and different according to the type of diagnosed commercial unit, includes but not limited to: one or more in vibration monitoring instrument, infrared thermography, ultrasonic detection equipment, current spectrum instrument, fluid ferrograph analyzer, fluid laser particle degree calculating instrument, laser velocity gauge and spot dynamic balance instrument.
In the method, the process that obtains of described commercial unit diagnostic data is:
Record commercial unit information;
According to the commercial unit information of calling, determine the commercial unit that will diagnose, control diagnostic device commercial unit is diagnosed, obtain described commercial unit diagnostic data.
In the method, commercial unit information includes but not limited to: commercial unit kind, number of units, model and structure and parameters, when storage, can be according to the operating area of commercial unit, such as boiler area or turbine area, create commercial unit structure tree, so that management.
Than existing device management software and fault diagnosis software:
Existing device management software all occurs with the form of similar " equipment account "; be that function is to record the critical information of each equipment; as putting equipment in service/installation/stop time; start and stop record and record of examination etc.; the object of software is just record; and for personnel, input by hand, its effect is equal to electronic equipment records originally.The technology content of existing device management software is lower and of a great variety, conventionally coordinates enterprise asset management to use, and has certain reference value in the work such as overhaul of the equipments.Further, existing fault diagnosis software is basic all divides according to different detection techniques, and configuration, take power plant as example respectively, and the software vibration testing equipment common and that power plant is used that carries out vibration analysis is supporting, for independently detecting analysis software; Seemingly, all the form with autonomous system represents the technology type such as ultrasonic and infrared.By contrast, the system that the embodiment of the present invention provides not only comprises equipment account terminal, the result of all right multiple detection means of integrating, contrast built-in device fault model and corresponding commercial unit diagnostic result, in the fault diagnosis of monomer commercial unit, accurately judge whether the reason that fault and fault produce, and provide detailed maintenance scheme.In actual applications, the system that the embodiment of the present invention provides can be got rid of the restriction of maintainer's factor, perfectly integrates plurality of devices fault detection technique.Make managerial personnel fully understand the incipient fault of commercial unit, avoid erroneous judgement.
Than existing remote diagnosis software:
The existing remote diagnosis software generally with general applicability, only has part to have remote diagnosis module for the software product of particular industry equipment design.The turbo generator supervision equipment of certain model for example, its software kit can long-range transmission commercial unit diagnostic data, realization is to the remote diagnosis of Turbo-generator Set state or monitoring, but this function is only for Turbo-generator Set, must coordinate relevant speciality hardware to use.And concerning the embodiment of the present invention, existing remote diagnosis software is only for specific commercial unit design, do not have ubiquity, and most commercial units in factory, do not have similar software to apply at all, only can take the modes such as artificial mail to complete remote diagnosis, the embodiment of the present invention has solved this problem, the ubiquity of remote diagnosis application is increased substantially, and reduced implementation cost.
The embodiment of the present invention has been carried out substantial improvement to existing maintenance model.
The scheme providing for several specific implementation example explanation embodiment of the present invention
Specific implementation example one
#2 major overhaul overhauling project in 2011, the method Diagnosis and maintenance that adopts the embodiment of the present invention to provide to 35 equipment of #2 unit, wherein boiler specialty is 16,17 of steam turbine professions, 2 of Additional Specialties, provide detailed diagnostics result.25 use oil masses are analyzed at the above equipment fluid of 50L, provided detailed diagnostics result, 2 equipment need be changed oil product, and 5 equipment need carry out oil strain.Adopt existing mode, during overhaul, all devices oil product all will be changed, and according to diagnosis oil analysis result provided by the invention, only changes 2 equipment fluid, has saved nearly 200,000 yuan of oil product renewal costs.In #2 major overhaul, according to diagnostic result, there are 3 equipment to reduce overhauling project (water supply pump motor is taken out rotor), saved nearly 20,000 yuan of recondition expense.
Specific implementation example two
The method Diagnosis and maintenance that adopts the embodiment of the present invention to provide to 38 equipment before #1 set optimization maintenance in 2011, wherein boiler specialty is 16,17 of steam turbine professions, 5 of Additional Specialties, provide detailed diagnostics result, find 5 of existing problems equipment.25 use oil masses are analyzed at the above equipment fluid of 50L, provided detailed diagnostics result, 1 equipment need be changed oil product, and 5 equipment need carry out oil strain.In the maintenance of #1 set optimization, 3 detections being found that there is to problem device (seal fan, open type pump, technique water pump) has increased turnaround plan, has improved equipment operational reliability.In-problem 5 equipment have been carried out to maintenance checking, had 4 device Diagnostics accurate, accuracy rate of diagnosis 80%.After year unit light maintenance in April of #1 unit to 2010 starts, operation, up in August, 2011 set optimization maintenance, has kept the situation of long period safe and stable operation continuously.In the maintenance of #1 set optimization, only spend the cost of overhaul more than 300 ten thousand, saved more than 100 ten thousand yuan of costs of overhaul.
Specific implementation example three
Other performance analyses
Adopt the method Diagnosis and maintenance that the embodiment of the present invention provides in commercial unit maintenance and overhaul management, to bring into play the effect of commercial unit " health care teacher ".Subsidiary engine equipment failure number of times in related factory in 2011 obviously reduces, and the unexpected damage accident of subsidiary engine equipment does not occur.Improved commercial unit reliability, greatly improved the accuracy of commercial unit maintenance simultaneously, effectively avoided crossing and overhauled and owe maintenance.Carry out after spot check periodical repair and the management of accurate spot check, by the equipment state of equipment being carried out grasp in regular spot check and professional accurate spot check work, part commercial unit has been carried out to repair based on condition of component, rationally extended the time between overhauls(TBO), shorten maintenance duration, effectively reduced the cost of overhaul.
More than lift preferred embodiment; the object, technical solutions and advantages of the present invention are further described; institute is understood that; the foregoing is only preferred embodiment of the present invention; not in order to limit the present invention; within the spirit and principles in the present invention all, any modification of doing, be equal to and replace and improvement etc., within all should being included in protection scope of the present invention.
Claims (10)
1. long-range accurate diagnosis and the maintenance system of commercial unit, is characterized in that, comprising: commercial unit remote diagnosis database, diagnostic model database, diagnostic device, expert terminals and plant terminal, wherein,
Equipment account terminal, for recording commercial unit information, accepts calling of plant terminal, and commercial unit information is offered to plant terminal;
Plant terminal, for according to the commercial unit information of calling from equipment account terminal, determines the commercial unit that will diagnose, controls diagnostic device commercial unit is diagnosed; According to the commercial unit diagnostic result or the maintenance information that receive from commercial unit remote diagnosis database, or receive the maintenance information from diagnostic model database, offer maintainer, supply maintainer with reference to commercial unit diagnostic result, or indication maintainer safeguard to commercial unit according to maintenance information;
Diagnostic device, under the control of plant terminal, diagnostic device is diagnosed commercial unit, and the commercial unit diagnostic data obtaining is sent to commercial unit remote diagnosis database;
Commercial unit remote diagnosis database, for storing the commercial unit diagnostic result corresponding to commercial unit diagnostic data, determines corresponding commercial unit diagnostic result according to the commercial unit diagnostic data receiving from diagnostic device, sends to plant terminal; Or the commercial unit diagnostic data receiving from diagnostic device is sent to diagnostic model database or sends to expert terminals, the maintenance information receiving from expert terminals is sent to plant terminal;
Diagnostic model database, for storing the maintenance information of corresponding commercial unit diagnostic data, receives after the commercial unit diagnostic data of commercial unit remote diagnosis database transmission, obtains corresponding maintenance information, sends to plant terminal;
Expert terminals, the commercial unit diagnostic data sending for receiving commercial unit remote diagnosis database, carries out, after remote diagnosis, being maintained information, sends to plant terminal.
2. the system as claimed in claim 1, is characterized in that, described diagnostic device is a plurality of, adopts different interfaces to connect respectively from commercial unit remote diagnosis database, carries out the diagnosis of corresponding different commercial units.
3. system as claimed in claim 2, it is characterized in that, described diagnostic device comprises: one or more in vibration monitoring instrument, infrared thermography, ultrasonic detection equipment, current spectrum instrument, fluid ferrograph analyzer, fluid laser particle degree calculating instrument, laser velocity gauge and spot dynamic balance instrument.
4. the system as claimed in claim 1, is characterized in that, described commercial unit information comprises: one or more in commercial unit kind, number of units, model and structure and parameters;
Described equipment account terminal, also for when storing described commercial unit information, according to the operating area storage of commercial unit.
5. the system as claimed in claim 1, is characterized in that, described commercial unit remote diagnosis database also, for being non-when abnormal when definite corresponding commercial unit diagnostic result, directly sends to plant terminal; When definite corresponding commercial unit diagnostic result is while being abnormal, the commercial unit diagnostic data receiving from diagnostic device is sent to diagnostic model database or sends to expert terminals.
6. long-range accurate diagnosis and the maintaining method of commercial unit, is characterized in that, the method comprises:
The storage of commercial unit remote diagnosis database is corresponding to the commercial unit diagnostic result of commercial unit diagnostic data;
During commercial unit diagnostic data that commercial unit remote diagnosis database receives from diagnostic device, determine corresponding commercial unit diagnostic result, send to plant terminal.
7. method as claimed in claim 6, is characterized in that, during the commercial unit diagnostic result of described definite correspondence, if this commercial unit diagnostic result is abnormal, the method also comprises:
The commercial unit diagnostic data receiving from diagnostic device is sent to diagnostic model database or sends to expert terminals, the maintenance information receiving from expert terminals is sent to plant terminal;
Or by diagnostic model database, stored the maintenance information of corresponding commercial unit diagnostic data, receive after the commercial unit diagnostic data of commercial unit remote diagnosis database transmission, obtain corresponding maintenance information, send to plant terminal.
8. method as claimed in claim 6, it is characterized in that, described diagnostic device is different and different according to the type of the commercial unit of diagnosis, comprising: one or more in vibration monitoring instrument, infrared thermography, ultrasonic detection equipment, current spectrum instrument, fluid ferrograph analyzer, fluid laser particle degree calculating instrument, laser velocity gauge and spot dynamic balance instrument.
9. method as claimed in claim 6, is characterized in that, the process that obtains of described commercial unit diagnostic data is:
Record commercial unit information;
According to the commercial unit information of calling, determine the commercial unit that will diagnose, control diagnostic device commercial unit is diagnosed, obtain described commercial unit diagnostic data.
10. method as claimed in claim 9, is characterized in that, commercial unit information comprises: one or more in commercial unit kind, number of units, model and structure and parameters.
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