CN105759731A - Novel operation state identification and early warning system - Google Patents
Novel operation state identification and early warning system Download PDFInfo
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- CN105759731A CN105759731A CN201410763850.7A CN201410763850A CN105759731A CN 105759731 A CN105759731 A CN 105759731A CN 201410763850 A CN201410763850 A CN 201410763850A CN 105759731 A CN105759731 A CN 105759731A
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention relates to a novel operation state identification and early warning system. The system is characterized in that the system comprises air shaft substations, a master control system, a remote diagnosis system, a wireless acquisition module and a network service station. The wireless acquisition module comprises base stations and nodes. Each node comprises a vibration temperature sensor, a DSP data processing plate and a wireless transmit-receive module. The wireless transmit-receive modules are connected with the base stations through a wireless network. The base stations are connected with the master control system through a ground ring network. The master control system, the air shaft substations, the remote diagnosis system and the network service station are connected mutually through the ground ring network. All wireless nodes in the network are in both-way communication with the base stations; and the nodes are not communicated mutually. Compared with the other two networks, the star network has the advantages of low overall power consumption, easy movement and easy expansion and the like.
Description
Technical field
The invention belongs to networking technology area, be specifically related to a kind of novel running status identification and early warning system.
Background technology
Coal Mine Electromechanical Equipment group is important equipment and the material base of coal production industry, and number of devices is many, and power is big.These equipment are once shutdown of breaking down, and the lighter affects yield, and severe one will cause great personnel casualty accidents.Therefore, large-scale key equipment safe and stable, long period, at full capacity, high-quality runs the economic benefit being not only related to enterprise, and is related to shaft production safety and social harmony.Even if some giant mechanical and electrical equipments configure some fault back-up protection functions at present, or carry out off-line instruments instrument routine inspection mode, but its defect yet suffers from: on the one hand, will put into substantial amounts of manpower and materials；On the other hand, owing to the polling period of equipment is longer, operations staff and management personnel can not understand the running status of equipment in real time, and equipment fault cannot find in early days, thus missing the best opportunity of process problem.Especially, some occasion of colliery, owing to the reason such as environment, position limits, it is difficult to carry out manual inspection.At present, English, various countries of U.S. extensively carry out the applied research of unit exception state identification and early warning technology in numerous industries, have leading position.Japan, then in civilian industry, as the industry development such as iron and steel, chemical industry is very fast, occupies clear superiority.According to investigation, current domestic electromechanical equipment abnormality identification and early warning technology also earn widespread respect and develop, extensive in sector applications such as aviation, traffic, petrochemical industry.But, in colliery, industry is started late, and technology is also immature, and the online colliery giant mechanical and electrical equipment group's abnormal operating condition identification being based particularly on wireless sensor network technology occurs but without product substantially with early warning net system.
Summary of the invention
Instant invention overcomes the deficiencies in the prior art, propose a kind of novel running status identification and early warning system, described system is with the systematology in modern science, cybernetics, reliability theory, theory of failure etc. for theoretical basis, with wireless sensor network for technological means, develop a set of online colliery giant mechanical and electrical equipment group's abnormal operating condition identification and early warning net system.This system combines the particularity of monitoring object, targetedly each crucial running state parameter is continuously monitored, equipment is made in good time evaluation, fault is given warning in advance and makes diagnosis, make enterprise that from planned maintenance, accident maintenance, the maintenance management of equipment is progressively transitioned into the preventative maintenance based on status monitoring, improve coal mine equipment management modernization level, create huge economic benefit.Described system data acquisition part forms by being deployed in monitored area substantial amounts of microsensor node, the network system of the self-organizing of a multi-hop is formed by the mode of radio communication, its objective is the information of perceptive object in perception collaboratively, collection and process network's coverage area, and be sent to observer.It is particularly suited for being deployed in the region of the such bad environments of mine, highly dangerous.
The technical scheme is that a kind of novel running status identification and early warning system, including ventilating shaft substation, master control system, remote diagnosis system, wireless acquisition module and network service station, described wireless acquisition module includes base station and node, described node includes vibration temperature sensor, DSP data process plate and radio receiving transmitting module, described radio receiving transmitting module is connected with base station by wireless network, described base station is connected with master control system by ground looped network, described master control system, ventilating shaft substation, remote diagnosis system and network service station are interconnected by ground looped network.
Described radio receiving transmitting module is provided with a configurable modem, supports different modulation formats so that it is the transfer rate of data reaches 500kbps.
Remote diagnosis system is based on the data of wireless acquisition module on-line monitoring unit, the real time datas such as the vibration signal that obtains according to on-line monitoring, procedure parameter, according to the analysis result of signal analysis module in master control system, extract the characteristic of reflection operating states of the units, and comprehensively analyze in conjunction with unit historical failure archives, the unit broken down is diagnosed.
Described remote diagnosis system is provided with early warning processing module, and the data that early warning processing module is after being processed by each channel acquisition compare with diagnostic criteria, it is judged that whether equipment is in normal operating condition.
There is advantages that
1, electromechanical equipment safe operating life of the present invention extends effect, is not less than 25%；
2, maintenance frequency of the present invention and maintenance cost reduce 50%；
3, wireless sensor network covering radius of the present invention is more than 50 meters；
4, wireless sensor network energy consumption of the present invention controls and agreement reasonability；
5, abnormality identification of the present invention and fault characteristic value identification error are less than 0.5%；
6, abnormal operating condition identification of the present invention and early warning system accuracy are more than 99.5%；
7, wireless sensor network base station of the present invention has ethernet interface and a standard communication protocol, and can directly and the seamless networking of colliery fiberoptic delay；
8, in inventive network, all radio nodes all carry out two-way communication with base station, do not communicate between each node.Star Network has overall power movement minimum, easy compared with other two kinds of networks, is prone to the advantages such as extension；
9, collection of the present invention and process the information of perceptive object in network's coverage area, and it is sent to observer.It is particularly suited for being deployed in the region of the such bad environments of mine, highly dangerous.
Accompanying drawing explanation
The present invention is further illustrated below in conjunction with the drawings and specific embodiments.
Fig. 1 is wireless sensor network theory of constitution block diagram of the present invention.
Fig. 2 is inventive network node structure schematic diagram.
Fig. 3 is inventive network intra-node theory diagram.
Fig. 4 is that DSP data of the present invention process plate composition schematic diagram.
Fig. 5 is architecture of base station schematic diagram of the present invention.
Fig. 6 is present system structured flowchart.
Fig. 7 is on-line vibration monitoring and fault diagnosis technology path schematic diagram of the present invention.
Fig. 8 is early warning handling process schematic diagram of the present invention.
In figure, 1, node；2, base station；3, ground monitoring main website；4, vibration temperature sensor；5, DSP data process plate；6, radio receiving transmitting module；7, battery supply；8, SRAM module；9, power supply；10, TMS320F2812 chip；11, digital 1/0 interface；12, eight road ADC；13, RS485/422 interface；14、JTAG；15, radio-frequency module；16, MSP430F1611 chip；17, power supply；18, Ethernet interface；19、USB；20, RS232 interface；21, master control system；22, remote diagnosis system；23, ventilating shaft substation；24, ground looped network；25, network service station；26, equipment to be checked；27, typical characteristic；28, fault diagnosis；29, maintenance of equipment；30, monitoring feature；31, passage is reported to the police；32, FFT；33, feature extraction；34, fault diagnosis；35, recording events；36, display prints.
Detailed description of the invention:
Referring to shown in Fig. 1 to Fig. 8, the present invention includes ventilating shaft substation 23, master control system 21, remote diagnosis system 22, wireless acquisition module and network service station 25, described wireless acquisition module includes base station 2 and node 1, described node 1 includes vibration temperature sensor 4, DSP data process plate 5 and radio receiving transmitting module 6, described radio receiving transmitting module 6 is connected with base station 2 by wireless network, described base station 2 is connected with master control system 21 by ground looped network 24, described node 1 is powered by battery supply 7, ground looped network 24 is ethernet network, described master control system 21 comprises ground monitoring main website 3, described master control system 21, ventilating shaft substation 23, remote diagnosis system 22 and network service station 25 are interconnected by ground looped network 24.
Described radio receiving transmitting module 6 is provided with a configurable modem, supports different modulation formats so that it is the transfer rate of data reaches 500kbps.
Remote diagnosis system 22 is based on the data of wireless acquisition module on-line monitoring unit, the real time datas such as the vibration signal that obtains according to on-line monitoring, procedure parameter, according to the analysis result of signal analysis module in master control system 21, extract the characteristic of reflection operating states of the units, and comprehensively analyze in conjunction with unit historical failure archives, the unit broken down is diagnosed.
The reason causing mechanical disorder and inefficacy is many-sided.Fault diagnosis subsystem is based on the on-line monitoring of unit, the real time datas such as the vibration signal that obtains according to on-line monitoring, procedure parameter, according to the analysis result of signal analysis module in signal analysis diagnosis server, extract the characteristic of reflection operating states of the units, and comprehensively analyze in conjunction with domain-specialist knowledge and unit historical failure archives, the unit broken down is diagnosed, it is determined that the position of fault, reason, type, character, and the reference proposition of maintenance is provided.Vibration monitoring includes equipment 26 to be checked, typical characteristic 27, fault diagnosis 28, maintenance of equipment 29, monitoring feature 30 with fault diagnosis technology route schematic diagram as it is shown in fig. 7, diagnosis algorithm.
Described remote diagnosis system 22 is provided with early warning processing module, the data that early warning processing module is after being processed by each channel acquisition compare with diagnostic criteria, from passage warning 31, FFT 32, feature extraction 33, fault diagnosis 34, recording events 35, finally arrive display printing 36, it is judged that whether equipment is in normal operating condition.
The present invention is applicable to mine application field, and if Mine Ventilator system, belt-conveying machine equipment are all be made up of rotatable parts and non-rotatable member, rotatable parts include rotor and the shaft coupling being connected with rotor, gear etc.；Non-rotatable member includes each class bearing, bearing block, casing and pedestal etc..Their state characteristic parameter, based on vibration parameters, takes into account the technological parameter such as temperature, pressure and the electrical parameter such as voltage, electric current simultaneously.Vibration-testing has its particularity, and one is that its vibration generally presents very strong periodicity, and two is that the main object of its vibration-testing is rotatable parts, i.e. rotating shaft to these main equipments.Status monitoring is primarily directed to these features to carry out.When equipment generation exception or when breaking down; during generally its Vibration Condition all can change; such as vibration amplitude change, frequency of vibration change, vibration phase change, direction of vibration change etc.; through test for many years and research; it is found that this feature of rotating machinery is particularly evident, therefore relevant with vibration parameter is by widely as the state characteristic parameter characterizing rotating machinery.Amplitude is the important parameter describing vibration equipment size.The equipment of normal operation, its vibration amplitude is generally stabilized in an allowed band, if amplitude there occurs change, just means that the state of equipment has had change.Therefore the monitoring of amplitude be can be used to the running status of judgment device.Amplitude can be divided into displacement amplitude, velocity amplitude, acceleration amplitude.Frequency of vibration can be divided into fundamental frequency (inverse in cycle) and frequency multiplication (each harmonic frequency), and it is another characteristic parameter describing machine state, is also the major parameter measured and analyze.Because specific frequency of vibration often corresponding certain fault, so monitoring and analysis to frequency of vibration are requisite in evaluation equipment state process.Phase place.Many equipment fault lists judge not to be easily distinguishable from amplitude spectrum, at this moment need phase information is further analyzed, to make accurate judgment.Owing to all kinds of fault of rotor is the symmetry destroying rotor to the direct result that rotor brings, making on the same cross section of rotor the phase contrast in time domain of the vibration signal both horizontally and vertically is no longer 90 degree, it is thus possible to carry out the type of failure judgement by the different characteristic of the phase contrast of horizontal direction signal and vertical direction signal on same cross section.It practice, except measuring except phase contrast on the different directions of same cross section, carry out the type of failure judgement also by the signal phase difference of different measuring points.Time domain waveform.The actually concentrated expression amplitude of vibration signal, frequency and phase place.Representing that Vibration Condition is the simplest, directly perceived by time domain waveform, and by the observation to time domain waveform, it is also possible to judge some common faults, for instance misalign, Rubbing faults, its time domain waveform just has obvious feature.Orbit of shaft center, orbit of shaft center is actually on axle center a bit relative to the movement locus of bearing block, and it reflects the actual motion situation of rotor visual in imagely.By the observation to orbit of shaft center, it is also possible to judge some common faults.Temperature.The electrical parameter such as electric current, voltage, by the giant mechanical and electrical equipment of motor-driven, the monitoring of the electrical parameter such as electric current, voltage is extremely important, because these parameters directly characterize the running status of equipment, the diagnosis of equipment fault is highly useful simultaneously.
Node 1 is not The more the better, with minimum sensor, and the sensitiveest operating mode measuring whole electromechanical equipment group to determine requisite node 1, and this is accomplished by the architectural characteristic to whole unit and makees to fully understand and serious analysis.For Diagnosing System for Oil Pump, to take into account the requirement in economy, efficiency etc. when carrying out measuring point position, can catch premised on the fault of unit, reasonable arrangement measuring point.For the vibration measurement in casing, the selection of measuring point is considered as environmental factors, it is to avoid select the place that high temperature, high humility, air outlet and variations in temperature are violent as node 1, to ensure the effectiveness measured.For reducing system cost, random vibration and impact shock for high frequency can only determine that a direction is node 1.But the determination vibration for low-frequency range must measure horizontal and vertical directions simultaneously, axial measuring point also should be increased if desired.The relation that tested Vibration Parameter is mutual.The leading indicator of vibration-testing is amplitude, and amplitude refers to the ultimate range of vibrating object deviation equilbrium position.Can represent with acceleration, speed, displacement.Accekeration can be tried to achieve by the second differential of the once differentiation of speed or displacement.Integration of acceleration is speed, and quadratic integral is displacement, all has integrating circuit in most vialogs.It will be apparent that velocity and acceleration is all relevant with frequency.If displacement is certain, then speed will increase with frequency and increase, and acceleration by with frequency square and increase.If acceleration is certain, then speed will increase with frequency and reduce, and displacement by with frequency square and reduce.In order to obtain the measurement parameter to Fault-Sensitive, should select to measure accordingly parameter according to the characteristic frequency of fault.Equally, between acceleration, speed and displacement, there is phase contrast, respectively pi/2 and π.That is advanced 90 ° of acceleration ratio speed, advanced 180 ° than displacement.Two different vibration sources all can have various phase places.Identical phase place is likely to cause resonance of being in step with, and produces serious consequence.If opposite in phase, then it is likely to cause vibration cancellation, plays damping effect.Therefore, phase place is also the important information of vibration performance.When frequency analysis, dynamic balancing measurement, oscillatory type are measured and judged resonance point, should ensure that the accuracy of amplitude measurement and phase measurement.
Need consider and note following factor with in test before testing.Understand the test principle of object and structure, if there is external stimuli vibration, in fact it could happen that fault and fault be reflected in which position, most sensitive in the change of which parameter.Understand the operation conditions of measurand, for instance, easily send out fault, the failure logging once occurred.Determine which data of purpose needs meeting measurement, tackle which parameter and be measured.Estimate the oscillatory type of measurand, level of shaking and issuable minimum and highest frequency, determine sensor type and the intermediate translator matched thereof and display recorder device according to environmental condition (such as temperature, humidity, electromagnetic field etc.) simultaneously.Draw the work block diagram of test system and the connection sketch of instrument, mark model and the sequence number of instrument, in order to the test installation of system, calibration and establishment test report.Determine the installation site of sensor, method and mounting fixing parts structure, evaluate whether because of the impact of sensor additional mass, test object to be impacted (such as: change original frequency of vibration, amplitude).Test process is tackled test environment and makes itemized record, in order to reference and timely some accidentalia of discovery when data analysis.Test process is answered " background noise " of running check test system, removes this some factors when analyzing.When measurement data being processed and analyzes, the protocol of test process should be consulted, if any Special Influence factor, means should be taked to eliminate its impact or reject the data being mixed with spurious signal, to ensure to obtain correct result.
DSP data process plate 5 have two-forty, in high precision, high reliability, including SRAM module 8, power supply 9, TMS320F2812 chip 10, digital 1/0 interface 11, eight road ADC12, RS485/422 interface 13 and JTAG14, it has been best suitable for digital algorithm and system controls.Requirement has hardware watchdog design, and program crashes and can reset automatically, and A/D interface, the sample frequency of up to 150K, data control in real time and process.Power supply, battery duplicate supply pattern, facilitate Different field to use.Supporting RS485 communication, low-power consumption, high reliability, volume are little, are suitable for embedded built-in and integration of equipments, are particularly suitable for battery powered equipment, facilitate external various kinds of sensors, meet monitoring requirements.
As shown in Figure 5, the single-chip microcomputer that base station 2 includes radio-frequency module 15, MSP430F1611 chip 16, power supply 17, Ethernet interface 18, USB19 and RS232 interface 20, MSP430F1611 chip 16 are 16, has higher performance, low in energy consumption, running voltage 1.8-3.6v.Ethernet interface 18 directly communicates with ground host computer with mine industrial optical fiber ring interfaces.
At occasion, chamber or acceptance region that some sensors and the direct line of data acquisition substation are restricted, electromechanical device state monitoring can adopt the manner.Node 1 is deployed in monitored area, is formed the network system of the self-organizing of a multi-hop by the mode of radio communication, its objective is the information of perceptive object in perception collaboratively, collection and process network's coverage area, and is sent to observer.It is particularly suited for being deployed in the region of the such bad environments of mine, highly dangerous.Good communication protocol is the premise of wireless system reliable communication, it is contemplated that the performance of system, reliability and power consumption, and bottom radio frequency communication network to select suitable topological structure.This is the basis of home control network communication protocol design.The present invention adopts Star Network.Star Network is a single-hop systems, and in network, all nodes 1 all carry out two-way communication with base station 2, do not communicate between each node 1.Star Network has overall power movement minimum, easy compared with other two kinds of networks, is prone to the advantages such as extension, but the communication distance between node 1 and base station 2 depends on the wireless signal coverage of individual node 1.
Claims (1)
1. a novel running status identification and early warning system, it is characterized in that: include ventilating shaft substation, master control system, remote diagnosis system, wireless acquisition module and network service station, described wireless acquisition module includes base station and node, described node includes vibration temperature sensor, DSP data process plate and radio receiving transmitting module, described radio receiving transmitting module is connected with base station by wireless network, described base station is connected with master control system by ground looped network, described master control system, ventilating shaft substation, remote diagnosis system and network service station are interconnected by ground looped network.
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| CN201410763850.7A CN105759731A (en) | 2014-12-13 | 2014-12-13 | Novel operation state identification and early warning system |
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| CN201410763850.7A CN105759731A (en) | 2014-12-13 | 2014-12-13 | Novel operation state identification and early warning system |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108459540A (en) * | 2017-02-20 | 2018-08-28 | 横河电机株式会社 | Field instrumentation and information providing method |
| US10921799B2 (en) * | 2017-05-10 | 2021-02-16 | Equipbit, Inc. | Motor driven equipment maintenance monitoring system |
| CN117032144A (en) * | 2023-09-08 | 2023-11-10 | 北京科创晶睿科技有限公司 | Equipment supervision system and method based on environment data |
-
2014
- 2014-12-13 CN CN201410763850.7A patent/CN105759731A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108459540A (en) * | 2017-02-20 | 2018-08-28 | 横河电机株式会社 | Field instrumentation and information providing method |
| CN108459540B (en) * | 2017-02-20 | 2021-06-11 | 横河电机株式会社 | On-site instrument and information providing method |
| US10921799B2 (en) * | 2017-05-10 | 2021-02-16 | Equipbit, Inc. | Motor driven equipment maintenance monitoring system |
| CN117032144A (en) * | 2023-09-08 | 2023-11-10 | 北京科创晶睿科技有限公司 | Equipment supervision system and method based on environment data |
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Application publication date: 20160713 |