CN104165138A - Pump group state online monitoring system and method - Google Patents
Pump group state online monitoring system and method Download PDFInfo
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- CN104165138A CN104165138A CN201410314088.4A CN201410314088A CN104165138A CN 104165138 A CN104165138 A CN 104165138A CN 201410314088 A CN201410314088 A CN 201410314088A CN 104165138 A CN104165138 A CN 104165138A
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Abstract
The invention relates to a pump group state online monitoring system and method. The monitoring system comprises a plurality of pump state sensors, a plurality of pump state data aggregation devices and an industrial personnel computer serving as a monitoring terminal, wherein the pump state sensors are installed on pumps in a one-to-one correspondence mode, the pump state data aggregation devices and the pump state sensors are in wireless connection, and the pump state data aggregation devices and the industrial personnel computer are in wireless connection or in wired connection. The monitoring method comprises the steps that vibration and temperature information of the pumps is collected by the pump state sensors in real time, transmitted to the pump state data aggregation devices wirelessly, processed in a concentrated mode and then transmitted to the industrial personnel computer, calculation and processing are conducted through the industrial personnel computer, the real-time states, the historical operation states and the fault diagnostic reports of the pumps are displayed, and the online real-time state monitoring on the pumps by a control center is achieved. Faults can be found in time and handled in time, and it is ensured that production is conducted normally.
Description
Technical field
The present invention relates to a kind of monitoring system, relate in particular to a kind of group of pump state on_line monitoring system and monitoring method thereof whether petroleum chemical enterprise's group of pump normally works of monitoring.
Background technique
Petrochemical industry is due to its flow process, and equipment is all under high temperature and high pressure environment, and the method that need to apply real-time state monitoring realizes management.Real-time state monitoring is to strengthen an important content of the large unit specialized management of petrochemical industry, and it directly reflects the quality of operating states of the units.At present, the emphasis of Domestic Petrochemical Enterprises on-line monitoring is quite crucial large-scale unit often, pressure group as gentle in the main air unit of catalytic cracking unit, the pneumatics unit of power house and the large-scale compressor of other devices etc., for some small-sized crucial rotating equipments (as pump, compressor, small-sized fan, micro-machine etc.) at scene, because it is worth low getting the brush-off.For these mini-plants, most enterprises also rest on the stage of off-line monitoring or manual inspection, periodic maintenance.And these units and mini-plant, general work under bad environment of living in, belongs to the multiple equipment of fault, and the quality of its running is related to the production status of enterprise, and Business Economic Benefit is also had to direct impact.
Summary of the invention
The present invention mainly solves original petroleum chemical enterprise and small-sized crucial rotating equipment is also rested on to the stage of off-line monitoring or manual inspection, periodic maintenance, cannot realize online real-time state monitoring, affects the normal technical problem of producing of enterprise; A kind of group of pump state on_line monitoring system and monitoring method thereof are provided, vibration and the temperature information of its energy Real-time Collection pump, automatically pump is carried out to fault diagnosis, the real-time status, history run state and the fault diagnosis report that on monitor terminal, show pump, realize group of pump state on-line real time monitoring, be convenient to find in time fault dealing with in time, guaranteeing that enterprise produces normally carries out.
Another object of the present invention is to provide a kind of group of pump state on_line monitoring system, its front-end collection to vibration and the temperature information of pump with wireless communication mode, be transferred to rear end, omitted additionally arranging of a large amount of cables, installation and maintenance is all very convenient.
Another object of the present invention is to provide a kind of group of pump state on_line monitoring system, the pump state sensor that it is used and pump status data converging device all have explosion-proof dustproof and waterproof performance, be adapted at working under the high temperature and high pressure environment of petroleum chemical enterprise, improve functional reliability.
Above-mentioned technical problem of the present invention is mainly solved by following technical proposals: group of pump state on_line monitoring system of the present invention, comprise a plurality of pump state sensors, several pump status data converging devices and as the process control machine of monitor terminal, pump state sensor described in one is installed on each pump that need to monitor, each pump status data converging device and a plurality of wireless being connected of pump state sensor, described pump status data converging device is wireless with described process control machine or wired being connected.A pump state sensor is installed on each pump that need to monitor, the work state information of pump state sensor Real-time Collection pump, involving vibrations information and temperature information, and be wirelessly sent to and have the pump of certain distance status data converging device with it, every pump status data converging device can be managed many pump state sensors, pump status data converging device is processed and gathers the data that receive, in wired or wireless mode, be transferred to process control machine again, process control machine can be managed many pump status data converging devices, process control machine is processed and is analyzed the status data of all pumps that receive, draw pump fault diagnosis report.Control signal on process control machine is passed to pump state sensor under also can be wireless again by pump status data converging device, and sensor can transmit according to the information obtaining.The technical program realizes the online real-time state monitoring of Surveillance center to pump, is convenient to find in time fault dealing with in time, guarantees that enterprise produces normally to carry out.And vibration and the temperature information of the pump that collects of pump state sensor be transferred to pump status data converging device with wireless communication mode, omitted additionally arranging of a large amount of cables, installation and maintenance is all very convenient.
Group of pump state on_line monitoring system also can comprise the server being connected on Local Area Network, and process control machine is also connected with Local Area Network.In this technological scheme, all status datas of the pump that process control machine receives are transferred to server by Local Area Network again, finally by server, the status data of all pumps is processed and analyzed, the real time data list and historical data list and the various collection of illustrative plates that form all pumps, draw pump fault diagnosis report.By Local Area Network, also can articulate other process control machines as monitor terminal, realize many process control machines and can to pump, carry out Real-Time Monitoring simultaneously, be convenient to complete better monitoring task.On server, can carry out user authority setting, comprise the authority settings such as super caretaker, caretaker and operator, different rights has different operating functions and look facility.
As preferably, described pump state sensor comprises housing and is located at the circuit board in housing, on circuit board, be welded with pump state detection circuit, described pump state detection circuit comprises central processing unit, vibration signals collecting unit, temperature signal collection unit, voltage detection unit and radio communication unit and provide the power subsystem of operating voltage for whole pump state detection circuit, described power subsystem is battery-powered, vibration signals collecting unit, temperature signal collection unit and radio communication unit are connected with described central processing unit respectively, the input end of described voltage detection unit is connected with the positive pole of described battery, the output terminal of voltage detection unit is connected with described central processing unit.Vibration signals collecting unit can adopt 3-axis acceleration sensor to realize, and radio communication unit can adopt the frequency of okperation of 433MHz, avoided 2.4GHz frequency penetrating power poor, be subject to the anomalous weather impacts such as sleet and be subject to the problems such as other electronic equipment interference.Pump state sensor is arranged on monitored pump, vibration signals collecting unit gathers pump three shaft vibration signals, temperature signal collection unit harvester pump work ambient temperature signal, the vibration data monitoring and temperature data are transferred to respectively central processing unit, through analysis and the processing of central processing unit, then data are sent to pump status data converging device by radio communication unit.Adopt powered battery mode, avoid circumscripted power line, install and use convenient.By voltage detection unit Real-time Collection battery electric quantity, and flow to central processing unit, by central processing unit, the charge value recording is sent to again to convergence device and the monitor terminal of far-end by radio communication unit, make monitor staff pass through the work electric weight that monitor terminal can be found sensor in time, once find that electric weight is not enough, can make in time respective handling, guarantee that sensor works under normal operating voltage always, guarantee the accuracy of monitored data.
As preferably, described housing comprises base and cover on the lid on base, and described circuit board is arranged in base, and described power subsystem is battery-powered, battery is contained in battery mounting box, battery mounting box is positioned on circuit board, and described lid is by battery cover in battery mounting box, and base top is provided with explosion-proof outside thread, lid bottom is provided with explosion-proof internal thread, base and lid are threaded, and described base both sides are respectively provided with a mounting ear for symmetry mutually, and mounting ear is provided with mounting hole.Base and lid are threaded by explosion-proof, and circuit board and battery are sealed in housing, reach the effect of explosion-proof dustproof and waterproof.Base and lid can adopt stainless steel or aluminium material, and battery mounting box adopts ABS material.
As preferably, on the inwall of described battery mounting box, be provided with symmetrically two cambered outwards grooves in footpath, in the bottom centre of battery mounting box and groove, be respectively provided with a spring, on the outer wall of battery mounting box, be provided with symmetrically two erection columns, battery mounting box is arranged on described base by erection column, is also provided with a plurality of plush coppers along outer wall circumference uniform distribution on the outer wall of battery mounting box.The spring of bottom centre is against on battery electrode, and other two springs are against the side of battery, plays shockproof antifrictional effect.The setting of plush copper, is convenient to battery mounting box and base clamping, further improves battery mounting box and is firmly connected with base.
As preferably, described pump status data converging device comprises box body and the pump status data be located in box body converges circuit, pump status data converges circuit and comprises wireless communication module, central processing module and serial ports modular converter and converge the power module that circuit provides operating voltage for whole pump status data, wireless communication module is connected with central processing module, central processing module is connected with serial ports modular converter again, wireless communication module and described wireless being connected of pump state sensor, serial ports modular converter is connected with described process control machine by 485 communication cables.Serial ports modular converter adopts 485 conversion chips, wireless communication module adopts 433MHz wireless radiofrequency transceiving chip and yagi antenna to realize, the frequency of okperation of 433MHz, avoided 2.46Hz frequency penetrating power poor, be subject to the impact of the anomalous weather such as sleet and be subject to the problems such as other electronic equipment interference, yagi antenna has good directivity, compared with dipole antenna, have high gain, telecommunication effect is good especially.
As preferably, at the bottom of described box body comprises box and lid, at the bottom of box and lid by explosion-proof, be threaded, side at the bottom of described box is provided with input wires terminal and the output wiring terminal extending in box body, and input wires terminal and output wiring terminal are threaded by explosion-proof respectively with at the bottom of described box; The back side at the bottom of described box is provided with four mounting ears, and four mounting ears lay respectively at four corners of base, and mounting ear is provided with mounting hole; The end face of described lid is provided with two boss and two fastening screw trip bolts, two boss lay respectively at left side and the right side of lid, described boss is provided with U-shaped groove, and point-blank, two fastening screw trip bolts lay respectively at the left side of boss, left side and the right of right side boss to the U-shaped groove of two boss.The inner termination of input wires terminal, output wiring terminal connects respectively wireless communication module, serial ports modular converter, the external end head of input wires terminal connects yagi antenna by communication cable, and the external end head of output wiring terminal connects process control machine by 485 communication cables.Lid and input, output wiring terminal all adopt explosion-proof screw connection structure, reach the effect of explosion-proof dustproof and waterproof.At the bottom of box and lid all adopt stainless steel or aluminium material or aluminum alloy material.By mounting ear, be convenient to pump status data converging device to be installed on body of wall or on other equipment, easy for installation, install firmly.
The monitoring method of group of pump state on_line monitoring system of the present invention is: by the status information of described pump state sensor Real-time Collection pump, three shaft vibration data and the temperature datas that status information comprises pump, and through caching process and data packing, be wirelessly sent to again described pump status data converging device, pump status data converging device is resolved and is processed the data that receive, be transferred to again described process control machine, process control machine is processed and is analyzed the pump status data receiving, demonstrate real-time status and the history run state of pump, pass through again method for diagnosing faults, judge pump in normal state or fault state and carry out normal state demonstration or fault state demonstration.Three shaft vibration information and temperature informations of Real-time Collection pump of the present invention, automatically pump is carried out to fault diagnosis, the real-time status, history run state and the fault diagnosis report that on monitor terminal, show pump, realize group of pump state on-line real time monitoring, be convenient to find in time fault dealing with in time, guaranteeing that enterprise produces normally carries out.
As preferably, described process control machine is processed the pump status data receiving, form data analysis collection of illustrative plates, data analysis collection of illustrative plates comprises total looks figure, tendency chart, waveform frequency spectrum figure, envelope spectrogram, three-dimensional spectrogram, holographic spectrogram, holographic envelope diagram and monodrome rod figure, by method for diagnosing faults, form the condition diagnosing report of each pump again.Total looks figure shows the running state of all pumps under wind field, can find out intuitively whether pump exists fault state of alarm.Tendency chart shows the vibration trend of single pump, also can show the tendency chart of a plurality of pumps simultaneously, to put together, contrasts and checks.Waveform frequency spectrum figure shows vibrational waveform figure and the spectrogram of single pump, by checking analysis collection of illustrative plates, real-time waveform and historical waveform can also be compared to analysis simultaneously.Envelope spectrogram shows the envelope spectrogram of pump vibration, can check analysis collection of illustrative plates, real-time envelope waveform and historical envelope waveform can also be compared to analysis simultaneously.Three-dimensional spectrogram: can select vibration or envelope three-dimensional spectrum, can also check the waveform frequency spectrum figure of certain point in three-dimensional collection of illustrative plates simultaneously, realize associated between collection of illustrative plates and collection of illustrative plates, simply, conveniently check.Holographic spectrogram, realizes the contrast of rumble spectrum of X-axis, Y-axis and three directions of Z axis of a pump, and the some directions that obtain pump from contrast exist undesired vibration, thereby judge the position that fault occurs.Holographic envelope diagram, realizes the contrast of vibration envelope collection of illustrative plates of X-axis, Y-axis and three directions of Z axis of a pump to be measured, and the some directions that obtain measuring point from contrast exist undesired vibration, thereby judge the position that fault occurs.Monodrome rod figure, the real-time vibrational state that shows three directions of all measuring points, picture and text combination, the left side understands the vibration-related information that shows certain direction of measuring point with form, the right shows the vibrational state of three directions with oil drum shape, can carry out associated between collection of illustrative plates and collection of illustrative plates simultaneously, realize a plurality of free hand drawings spectrums and check with the switching of a plurality of collection of illustrative plates.Pump status information direct display, clear, can also carry out various contrasts, is convenient to find fault, judges in time abort situation.
As preferably, described method for diagnosing faults comprises: the alarm threshold that each pump is set, alarm threshold comprises high report value and high report value, the height report value of the pump status data collecting and setting, high report value are compared, when pump status data is less than high report value, be judged as pump and normally move, do not have fault, it is green that the pump icon showing on process control machine is; When pump status data is greater than high report value and while being less than high report value, is judged as high report to report to the police, it is yellow that the pump icon showing on process control machine is; When pump status data is greater than high report value, be judged as high report and report to the police, the pump icon showing on process control machine takes on a red color.Pump state direct display, clear, is convenient to find in time fault.
As preferably, described method for diagnosing faults is: adopt multi-variate statistical analysis, by principal component analysis, independent component analysis, core principal component analysis four kind methods separated with blind source are unified in higher-order statistics and extract, polynary redundancy feature merges under three subsystems separated with multidimensional measure signal, with multi-variate statistical analysis, described pump status information is carried out to feature extraction, the analysing and processing of signal analysis and state identification, for multivariate statistics characteristic evaluating and On The Choice, status information with low-dimensional principal component character representation pump, set up a kind of average degree of correlation rule and assess the state that each principal component depicts pump, and choose the comprehensive of low-dimensional principal component character representation pump status flag.The present invention utilizes Multielement statistical analysis method to mixed signal separation and analysing and processing and more effective new statistical nature is expressed and the machine performance pattern of the pump of classifying to extracting in multidimensional signal, thereby realize fault diagnosis, the regularity having had and strong receptance to pump state.Principal component analysis (PCA), independent component analysis (ICA), four kinds of Multivariates of core principal component analysis (KPCA) separated with blind source (BSS) are applied in the present invention, and be unified under higher-order statistics extraction, polynary redundancy feature fusion these three subsystems separated with multidimensional measure signal.Higher-order statistics extracts the higher-order statistics that can extract multidimensional or one-dimensional measurement signal, and this statistical information has embodied the essential attribute of pump state model, embodiment device running state that can be more responsive than original measurement signal.Polynary redundancy feature merges can extract the statistical framework making new advances from polynary primitive character, and these new features are than primitive character is more sane, cluster is better, has realized the more Precise Diagnosis to pump running state.The separation of multidimensional measure signal can be isolated the signal component of certain critical component of reflection from multidimensional measure signal, can judge more easily accordingly the failure condition of these parts, is a kind of new pump state analysis approach.The oscillating signal of pump has always shown the mixing of multichannel transmission of signal, and the signal that each pump state sensor obtains not is the actual vibration signal of surveyed location component, but the coupling of a plurality of vibration source signals.By Multielement statistical analysis methods such as principal component analysis, independent component analysis and core principal component analysis, to mixed signal separation and analysing and processing and to extracting more effectively new statistical nature in multidimensional signal, express and the pump state model of classifying, thereby realize the fault diagnosis to pump state.The technical program can be found pump initial failure accurate failure judgement situation, improved the availability of pump, reduce as much as possible cycle and the financial cost of care and maintenance, can also fundamentally solve the problem that maintenance is not enough and surplus is keeped in repair in equipment periodic maintenance.Can ensure the safe and reliable efficient operation of petroleum chemical enterprise's pump, prevention breaks down, and the accident of stopping occurs.
The invention has the beneficial effects as follows: by vibration and the temperature information of pump state sensor Real-time Collection pump, and radio to pump status data converging device, after focusing on, be transferred to again the process control machine of Surveillance center, by process control machine, pump is carried out to fault diagnosis, the real-time status, history run state and the fault diagnosis report that on process control machine, show pump, realize group of pump state on-line real time monitoring, be convenient to find in time fault dealing with in time, guaranteeing that enterprise produces normally carries out.And with wireless mode, carry out communication between pump state sensor and pump status data converging device, and omitted additionally arranging of a large amount of cables, installation and maintenance is all very convenient.
Accompanying drawing explanation
Fig. 1 is a kind of system linkage structure block diagram of group of pump state on_line monitoring system in the present invention.
Fig. 2 is a kind of stereo decomposing structural representation of pump state sensor in the present invention.
Fig. 3 is a kind of plan structure schematic diagram of the base of pump state sensor in the present invention.
Fig. 4 is a kind of perspective view of the battery mounting box of pump state sensor in the present invention.
Fig. 5 is a kind of circuit theory linkage structure block diagram of pump state sensor in the present invention.
Fig. 6 is a kind of main TV structure schematic diagram of pump status data converging device in the present invention.
Fig. 7 is a kind of side-looking structural representation of pump status data converging device in the present invention.
Fig. 8 is a kind of circuit theory linkage structure block diagram of pump status data converging device in the present invention.
1. circuit boards in figure, 2. central processing unit, 3. vibration signals collecting unit, 4. temperature signal collection unit, 5. radio communication unit, 6. power subsystem, 7. antenna, 8. voltage detection unit, 9. base, 10. lid, 11. battery mounting boxes, 12. batteries, 13. explosion-proof outside threads, 14. explosion-proof internal threads, 15. mounting ears, 16. mounting holes, 17. grooves, 18. springs, 19. erection columns, 20. plush coppers, 21. wireless communication modules, 22. central processing modules, 23. serial ports modular converters, 24. power modules, 27. yagi antennas, 28.485 communication cables, at the bottom of 29. boxes, 30. lids, 31. input wires terminals, 32. output wiring terminals, 33. mounting ears, 34. mounting holes, 35. boss, 36.U type groove, 37. fastening screw trip bolts, 100. pump state sensors, 200. pump status data converging devices, 300. process control machine, 400. server, 500. Local Area Network.
Embodiment
Below by embodiment, and by reference to the accompanying drawings, technological scheme of the present invention is described in further detail.
Embodiment: the group of pump state on_line monitoring system of the present embodiment, as shown in Figure 1, comprise pump state sensor 100, pump status data converging device 200, server 400 and as the process control machine 300 of monitor terminal, it is a plurality of how many pump state sensors can arrange according to the pump of need monitorings, pump status data converging device according to pump state sensor number also can arrange a plurality of.A pump state sensor 100 is installed on a pump, a pump status data converging device 200 can carry out wireless being connected with a plurality of pump state sensors 100, in Fig. 1, dotted line refers to wireless connections, a plurality of pump status data converging devices 200 are connected with process control machine 300 by 485 communication cables, and process control machine 300 and server 400 are all connected to Local Area Network 500.
As shown in Figure 2 and Figure 3, pump state sensor 100 comprises housing, and circuit board 1, battery mounting box 11 and battery 12 are installed in housing, is welded with pump state detection circuit on circuit board 1.Housing comprises base 9 and covers on the lid 10 on base 9, explosion-proof outside thread 13 is arranged at base 9 tops, explosion-proof internal thread 14 is arranged at lid 10 bottoms, base 9 is closely connected by explosion-proof screw thread with lid 10, respectively there is a mounting ear 15 for symmetry mutually base 9 both sides, on mounting ear 15, there is kidney-shaped mounting hole 16, be convenient to be installed on monitored pump.Base 9 sides are provided with antenna 7 vertically upward.Circuit board 1 is arranged in base 9, battery mounting box 11 is positioned on circuit board 1, battery 12 is contained in battery mounting box 11, as shown in Figure 4, on the inwall of battery mounting box 11, there are symmetrically two cambered outwards grooves 17 in footpath, in the bottom centre of battery mounting box 11 and groove 17, respectively there is a cone shaped spring 18, the spring of bottom centre is against on battery electrode, other two springs are against the side of battery, play shockproof antifrictional effect, on the outer wall of battery mounting box 11, there are symmetrically two erection columns 19, battery mounting box 11 is arranged on base 9 by erection column 19, on the outer wall of battery mounting box 11, also have four plush coppers 20 along outer wall circumference uniform distribution, with with base clamping, improve steadiness is installed, lid is connected with whorl of base, lid 10 covers on battery 12 in battery mounting box 11 simultaneously.Base and lid adopt stainless steel, and battery mounting box adopts ABS material.As shown in Figure 5, pump state detection circuit comprises central processing unit 2, vibration signals collecting unit 3, temperature signal collection unit 4, radio communication unit 5 and voltage detection unit 8 and provides the power subsystem 6 of operating voltage for whole pump state detection circuit, power subsystem 6 is powered by battery 12, vibration signals collecting unit 3, temperature signal collection unit 4 and radio communication unit 5 are connected with central processing unit 2 respectively, the input end of voltage detection unit 8 is connected with the positive pole of battery, and the output terminal of voltage detection unit 8 is connected with central processing unit 2.Central processing unit adopts single-chip microcomputer, radio communication unit adopts 433MHz wireless radiofrequency transceiving chip, the respective pin of 433MHz wireless radiofrequency transceiving chip is connected with antenna 7, and vibration signals collecting unit adopts 3-axis acceleration sensor, and temperature signal collection unit adopts temperature transducer.Voltage detection unit comprises comparator, adopts electric resistance partial pressure, gathers charged battery voltage, comparator is connected into the mode of voltage follower, then is configured to the built-in AD input channel of single-chip microcomputer.
As shown in Figure 6, Figure 7, pump status data converging device 200 comprises box body and the pump status data that is arranged in box body converges circuit.Box body comprises at the bottom of square box 29 and circular lid 30, and the opening at the bottom of square box is also rounded, lid 30 by explosion-proof screw thread and box at the bottom of 29 circular open be tightly connected.At the bottom of box, there is input wires terminal 31 and the output wiring terminal 32 extending in box body 29 side, and input wires terminal 31 and output wiring terminal 32 29 are threaded by explosion-proof respectively with at the bottom of box.At the bottom of box, 29 the back side is connected with 33, four mounting ears 33 of four mounting ears and lays respectively at the bottom of box four corners of 29, has mounting hole 34, so that pump status data converging device is installed on wall on mounting ear 33.On the end face of lid 30, there are two boss 35 and two fastening screw trip bolts 37, two boss 35 lay respectively at left side and the right side of lid 30, on boss 35, there is U-shaped groove 36, point-blank, two fastening screw trip bolts 37 lay respectively at the left side of boss 35, left side and the right of right side boss 35 to the U-shaped groove 36 of two boss 35.In the present embodiment, at the bottom of box and lid all adopt thickening type stainless steel.As shown in Figure 8, pump status data converges circuit and comprises wireless communication module 21, central processing module 22 and serial ports modular converter 23 and converge the power module 24 that circuit provides operating voltage for whole pump status data, wireless communication module 21 is connected with central processing module 22, central processing module 22 is connected with serial ports modular converter 23 again, serial ports modular converter 23 is connected with output wiring terminal 32, one end of output wiring terminal 32 again with 485 communication cables 28 is connected, and the other end of 485 communication cables 28 is connected with process control machine 200.Central processing module adopts single-chip microcomputer, serial ports modular converter adopts 485 conversion chips, wireless communication module 21 and a plurality of wireless being connected of pump state sensor 100, wireless communication module 21 comprises 433MHz wireless radiofrequency transceiving chip, the respective pin of 433MHz wireless radiofrequency transceiving chip is connected with input wires terminal 31, connecting communication cable on input wires terminal 31, this communication cable is connected with yagi antenna 27 again, yagi antenna 27 is installed in two U-shaped grooves 36 of lid 30, by two fastening screw trip bolts 37, yagi antenna 27 is fastened on lid 30 again, guarantee that antenna is easy for installation, install firm.
The monitoring method of above-mentioned group of pump state on_line monitoring system is: by the status information of pump state sensor 100 Real-time Collection pumps, three shaft vibration data and the temperature datas that status information comprises pump, and through caching process and data packing, be wirelessly sent to again pump status data converging device 200, 200 pairs of data that receive of pump status data converging device are resolved and are processed, be transferred to again process control machine 300, the pump status data that 300 pairs of process control machines receive is processed and is analyzed, adopt multi-variate statistical analysis, by principal component analysis, independent component analysis, core principal component analysis four kind methods separated with blind source are unified in higher-order statistics and extract, polynary redundancy feature merges under three subsystems separated with multidimensional measure signal, with multi-variate statistical analysis, described pump status information is carried out to feature extraction, the analysing and processing of signal analysis and state identification, for multivariate statistics characteristic evaluating and On The Choice, status information with low-dimensional principal component character representation pump, set up a kind of average degree of correlation rule and assess the state that each principal component depicts pump, and choose the comprehensive of low-dimensional principal component character representation pump status flag, form data analysis collection of illustrative plates, data analysis collection of illustrative plates comprises total looks figure, tendency chart, waveform frequency spectrum figure, envelope spectrogram, three-dimensional spectrogram, holographic spectrogram, holographic envelope diagram and monodrome rod figure, by each collection of illustrative plates, can check real-time running state and the history run state of pump, in addition, the alarm threshold of each pump is set in process control machine, alarm threshold comprises high report value and high report value, the height report value of the pump status data collecting and setting, high report value are compared, when pump status data is less than high report value, be judged as pump and normally move, do not have fault, it is green that the pump icon showing on process control machine is, when pump status data is greater than high report value and while being less than high report value, is judged as high report to report to the police, it is yellow that the pump icon showing on process control machine is, when pump status data is greater than high report value, be judged as high report and report to the police, the pump icon showing on process control machine takes on a red color.In addition, also have the electric weight of a pump state sensor to report to the police, when the battery electric quantity of pump state sensor is during lower than some charge values, just there will be electric weight to report to the police, in the interface that battery icon can show at process control machine, glimmer, prompting electric weight is not enough, is convenient to deal with in time, to obtain reliable monitor value.Finally the running state of each pump is formed to a diagnosis report automatically, be convenient to integral body and check pump information.
In the present embodiment, the calculating of waveform frequency spectrum figure adopts FFT Fourier fast transform algorithm.Algorithm principle and formula are as follows: the Fourier transformation of aperiodicity continuous time signal x (t) can be expressed as
What in formula, calculate is the continuous frequency spectrum of signal x (t).But that can access in actual control system is the discrete sampling value x (nT) of continuous signal x (t).Therefore need to utilize discrete signal x (nT) to calculate the frequency spectrum of signal x (t).
There is limit for length's discrete signal x (n), n=0,1 ..., the DFT of N-1 is defined as:
Can find out, DFT need to calculate about N2 multiplication and N2 sub-addition.When N is larger, this amount of calculation is very large.Utilize symmetry properties and the periodicity of WN, N point DFT is decomposed into the DFT that two N/2 are ordered, and such two total amounts of calculation of N/2 point DFT are original half, i.e. (N/2) 2+ (N/2) 2=N2/2, can continue like this to decompose, N/2 is decomposed into N/4 point DFT etc. again.The DFT of ordering for N=2m can be decomposed into the DFT of 2, and its amount of calculation can be reduced to (N/2) log2N multiplication and Nlog2N sub-addition like this.
X (n) is decomposed into two sequence sums of even number and odd number,
x(n)＝x
1(n)+x
2(n)
The length of x1 (n) and x2 (n) is all N/2, and x1 (n) is even number sequence, and x2 (n) is odd number sequence,
Due to
?
Wherein X1 (k) and X2 (k) are respectively the N/2 point DFT of x1 (n) and x2 (n).Because X1 (k) and X2 (k) all be take N/2 as the cycle, and WN k+N/2=-WN k, so X (k) can be expressed as again:
The computing of above formula is referred to as butterfly computation.The rest may be inferred, through m-1 decomposition, finally N point DFT is decomposed into N/2 2 DFT.The principle of fft algorithm is to go to realize large-scale conversion by many little conversion that are more prone to carry out, and has reduced computing requirement, has improved arithmetic speed.
Certainly the pump status information receiving can be processed also and can on server, be processed on process control machine, by Local Area Network, also can articulate other process control machines as monitor terminal, realizing many process control machines can carry out Real-Time Monitoring to pump simultaneously, is convenient to complete better monitoring task.On server, can carry out user authority setting, comprise the authority settings such as super caretaker, caretaker and operator, different rights has different operating functions and look facility.
Claims (10)
1. a group of pump state on_line monitoring system, it is characterized in that comprising a plurality of pump state sensors (100), several pump status data converging devices (200) and as the process control machine (300) of monitor terminal, pump state sensor (100) described in one is installed on each pump that need to monitor, each pump status data converging device (200) and wireless being connected of a plurality of pump state sensors (100), described pump status data converging device (200) is wireless with described process control machine (300) or wired being connected.
2. group of pump state on_line monitoring system according to claim 1, it is characterized in that described pump state sensor (100) comprises housing and is located at the circuit board (1) in housing, circuit board is welded with pump state detection circuit on (1), described pump state detection circuit comprises central processing unit (2), vibration signals collecting unit (3), temperature signal collection unit (4), voltage detection unit (8) and radio communication unit (5) and provide the power subsystem (6) of operating voltage for whole pump state detection circuit, described power subsystem (6) is battery-powered, vibration signals collecting unit (3), temperature signal collection unit (4) and radio communication unit (5) are connected with described central processing unit (2) respectively, the input end of described voltage detection unit (8) is connected with the positive pole of described battery, the output terminal of voltage detection unit (8) is connected with described central processing unit (2).
3. group of pump state on_line monitoring system according to claim 2, it is characterized in that described housing comprises base (9) and covers on the lid (10) on base (9), described circuit board (1) is arranged in base (9), described power subsystem (6) is powered by battery (12), battery (12) is contained in battery mounting box (11), battery mounting box (11) is positioned on circuit board (1), described lid (10) covers on battery (12) in battery mounting box (11), base (9) top is provided with explosion-proof outside thread (13), lid (10) bottom is provided with explosion-proof internal thread (14), base (9) and lid (10) are threaded, described base (9) both sides are respectively provided with a mounting ear (15) for symmetry mutually, mounting ear (15) is provided with mounting hole (16).
4. group of pump state on_line monitoring system according to claim 3, on the inwall of the battery mounting box (11) described in it is characterized in that, be provided with symmetrically two cambered outwards grooves in footpath (17), in the bottom centre of battery mounting box (11) and groove (17), be respectively provided with a spring (18), on the outer wall of battery mounting box (11), be provided with symmetrically two erection columns (19), it is upper that battery mounting box (11) is arranged on described base (9) by erection column (19), is also provided with a plurality of plush coppers along outer wall circumference uniform distribution (20) on the outer wall of battery mounting box (11).
5. group of pump state on_line monitoring system according to claim 1, it is characterized in that described pump status data converging device (200) comprises box body and the pump status data be located in box body converges circuit, pump status data converges circuit and comprises wireless communication module (21), central processing module (22) and serial ports modular converter (23) and converge the power module (24) that circuit provides operating voltage for whole pump status data, wireless communication module (21) is connected with central processing module (22), central processing module (22) is connected with serial ports modular converter (23) again, wireless communication module (21) and described wireless being connected of pump state sensor (100), serial ports modular converter (23) is connected with described process control machine (300) by 485 communication cables (28).
6. group of pump state on_line monitoring system according to claim 5, (29) and lid (30) at the bottom of box body described in it is characterized in that comprises box, at the bottom of box, (29) and lid (30) are threaded by explosion-proof, at the bottom of described box, the side of (29) is provided with input wires terminal (31) and the output wiring terminal (32) extending in box body, input wires terminal (31) and output wiring terminal (32) respectively with described box at the bottom of (29) by explosion-proof, be threaded; At the bottom of described box, the back side of (29) is provided with four mounting ears (33), and four mounting ears (33) lay respectively at four corners of base (29), and mounting ear (33) is provided with mounting hole (34); The end face of described lid (30) is provided with two boss (35) and two fastening screw trip bolts (37), two boss (35) lay respectively at left side and the right side of lid (30), described boss (35) is provided with U-shaped groove (36), point-blank, two fastening screw trip bolts (37) lay respectively at the left side of left side boss (35) and the right of right side boss (35) to the U-shaped groove (36) of two boss (35).
7. the monitoring method of a group of pump state on_line monitoring system as claimed in claim 1, it is characterized in that the status information by described pump state sensor (100) Real-time Collection pump, three shaft vibration data and the temperature datas that status information comprises pump, and through caching process and data packing, be wirelessly sent to again described pump status data converging device (200), pump status data converging device (200) is resolved and is processed the data that receive, be transferred to again described process control machine (300), process control machine (300) is processed and is analyzed the pump status data receiving, demonstrate real-time status and the history run state of pump, pass through again method for diagnosing faults, judge pump in normal state or fault state and carry out normal state demonstration or fault state demonstration.
8. group of pump state on_line monitoring method according to claim 7, process control machine (300) described in it is characterized in that is processed the pump status data receiving, form data analysis collection of illustrative plates, data analysis collection of illustrative plates comprises total looks figure, tendency chart, waveform frequency spectrum figure, envelope spectrogram, three-dimensional spectrogram, holographic spectrogram, holographic envelope diagram and monodrome rod figure, by method for diagnosing faults, form the condition diagnosing report of each pump again.
9. according to the group of pump state on_line monitoring method described in claim 7 or 8, it is characterized in that described method for diagnosing faults comprises: the alarm threshold that each pump is set, alarm threshold comprises high report value and high report value, the height report value of the pump status data collecting and setting, high report value are compared, when pump status data is less than high report value, be judged as pump and normally move, do not have fault, the upper pump icon showing of described process control machine (300) is green; When pump status data is greater than high report value and while being less than high report value, is judged as high report to report to the police, the upper pump icon showing of process control machine (300) is yellow; When pump status data is greater than high report value, be judged as high report and report to the police, the upper pump icon showing of process control machine (300) takes on a red color.
10. according to the group of pump state on_line monitoring method described in claim 7 or 8, it is characterized in that described method for diagnosing faults is: adopt multi-variate statistical analysis, by principal component analysis, independent component analysis, core principal component analysis four kind methods separated with blind source are unified in higher-order statistics and extract, polynary redundancy feature merges under three subsystems separated with multidimensional measure signal, with multi-variate statistical analysis, described pump status information is carried out to feature extraction, the analysing and processing of signal analysis and state identification, for multivariate statistics characteristic evaluating and On The Choice, status information with low-dimensional principal component character representation pump, set up a kind of average degree of correlation rule and assess the state that each principal component depicts pump, and choose the comprehensive of low-dimensional principal component character representation pump status flag.
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