CN105785961B - The information collection of forging machine tool operating condition and analysis system based on technology of Internet of things - Google Patents
The information collection of forging machine tool operating condition and analysis system based on technology of Internet of things Download PDFInfo
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- CN105785961B CN105785961B CN201610330738.3A CN201610330738A CN105785961B CN 105785961 B CN105785961 B CN 105785961B CN 201610330738 A CN201610330738 A CN 201610330738A CN 105785961 B CN105785961 B CN 105785961B
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Abstract
The invention discloses a kind of information collection of forging machine tool operating condition and analysis system based on technology of Internet of things, system is mainly that the operating status analog quantity of forging machine tool is obtained by sensor, the working condition switching value for obtaining forging machine tool is acquired by the signaling point to PLC, these information content pass to the processor chips of data collection station by the processing of data collection station interface circuit, then Cloud Server is passed to by GPRS (General Packet Radio Service) communication module, convenient for the shared of data.Cloud data are analyzed in real time by server embedded software, on the one hand, client is used as lathe, the operation report or warning information of lathe can be obtained by PC, the state of lathe is monitored at any time, and can obtain fault diagnosis report from lathe seller technical staff；On the other hand, operational efficiency, the working curve etc. that can inquire lathe by PC at any time as seller technical staff, to understand the health status of lathe in real time, in time judge failure.
Description
Technical field
The invention belongs to Internet of Things application fields, especially can using industrial embedded system and GPRS wireless transmission come
The transmission for realizing acquisition data is stored and is handled using Cloud Server, and carries out data analysis by software, obtains the fortune of lathe
Long-range monitoring is really realized in row state, energy consumption, efficiency analysis.
Background technique
The equipment that forging machine tool is metal and mechanical cold working, general relatively large and complicated, processing technology multiplicity.One
Denier lathe breaks down, maintenance it is professional stronger, and will affect the quality of converted products, result even in the hair of accident
It is raw.Therefore status monitoring is carried out to forging machine tool, to realize that early warning is highly important to the failure that may occur.Traditional forging
The realization of press bed monitoring and fault diagnosis is to read instrument and meter using scene, manually carries out failure further according to the data of record
Diagnosis, enterprise usually spend a large amount of manpower financial capacities thus.With the arrival in industrial 4.0 epoch, Internet of Things and big data analysis skill
Art constantly improve, and also more extensively, Mechanical course industrial expansion has welcome new situation to application field.It will currently, being in
Technology of Internet of things be applied to machine tool monitoring in the extensive sprouting stage, technology of Internet of things application so that lathe connection
Net is possibly realized with on-line monitoring, thus greatly reduces the investment of human and material resources.
But PC platform, network are mainly based upon with analysis method currently based on the acquisition of the machine tool data of technology of Internet of things
Communication mode is mostly the wired network communication mode of PC platform, be there is also some problems.Such as: acquisition platform is mostly flat dependent on PC
Platform, the volume of common computer is big, power consumption is high, is unsuitable for adverse circumstances work, and cost is relatively high；To acquisition data using not
It is enough abundant, lack profound information excavating；Real-time needs to be further increased.
A kind of numerically controlled machine remote monitoring and fault diagnosis system is disclosed in existing patent document CN102566503A, it should
System acquires the status information data of lathe using sensor, and transfers data to remote server by GPRS network, by
Service management and expert system module in server handle the data transmitted, obtain processing result and return to
Failure lathe realizes the remote monitoring and diagnostics to numerically-controlled machine tool.The deficiency of the system is the remote server
Data management is complicated, limited storage space, inelastic spatial spread ability, cannot automatically generate lathe operation report, use
Family is inconvenient using data.
Summary of the invention
Existing lathe data collection and transmission there are aiming at the problem that, the present invention provides a kind of new based on object
The forging machine tool operating condition information collection of networking technology and analysis system, acquisition platform depend on the industry based on ARM technology
Embedded system platform, it is strong real-time, small in size, low in energy consumption, it is suitable for industrial environment；Data transmission uses GPRS network, can
With directly with Internet intercommunication, network transmission speed is high, ensure that the timeliness of data；Data storage with processing using
The difficulty of Cloud Server, data management reduces, and extension storage space and data access are convenient.
In order to achieve the above objectives, technical solution provided by the invention are as follows:
The information collection of forging machine tool operating condition and analysis system is made of 4 big modules.As shown in Fig. 1, by
The four module that dotted line frame is framed is data acquisition module, data transmission module, data management module and data sharing respectively
Module.Each module device mainly includes sensor, PLC, embedded system, GPRS DTU, Cloud Server and PC.
The data acquisition module mainly includes displacement sensor, temperature sensor, current sensor, liquid level sensor
And PLC.It includes the analog quantitys such as spindle motor current, spindle power, temperature that sensor, which is mainly used for acquisition, by Machine Tool Electric Appliance electricity
The acquisition of road and PLC signaling point obtains the information such as energized state, main shaft start and stop, the coolant liquid switch of lathe.
The data transmission module mainly includes embedded system, GPRS DTU (General Packet Radio
Service Data Transfer unit) and mobile network communication.Interface of Embedded System circuit is used for the input of PLC is defeated
The signal of on-off model and sensor sends processor chips ARM to by signal processing appropriate and A/D conversion out.GPRS
DTU is used to exchange information with the external world, signal can be connected to Internet by GSM mobile communication, and then pass to middle calculation
According to library.
The data management module is mainly cloud server cluster, including central database, Web server and data point
Analyse server, for be managed collectively acquisition data, and carry out data analysis processing, generate operating status report, product energy consumption,
The analysis reports such as efficiency facilitate the inquiry of data and share.
The data sharing module is mainly personal computer, for the shared of data.One side lathe seller
Technical staff can obtain the operating status of lathe according to the analysis of data, make to the failure being likely to occur and timely judging, and
The scheme of product improvement can be proposed according to this, generate remote fault diagnosis report and conditions of machine tool report is supplied to client；Another party
Face client can be inquired at any time by client-side program, monitor the operating status of lathe at any time.
The step of system information is transmitted:
(1) cloth displacement sensor, temperature sensor, current sensor and liquid level sensor etc. on forging machine tool, benefit
With analog quantity informations such as sensor perception lathe spindle motor current, temperature.These information contain machine tool information abundant, such as
The important informations such as associated cutter state of wear, machine vibration signal, the energy consumption of lathe, failure exception.
(2) switching value information is acquired to the signaling point of PLC.By reading the I/O state of PLC, to obtain the energization of lathe
The information such as state, main shaft start and stop, coolant liquid switch.
(3) interface circuit of embedded system passes through the signal of sensor and PLC in the step (1), step (2) suitable
When processing (such as filtering, level conversion, A/D conversion) be converted into the acceptable signal of processor chips, be transmitted to chip
Input port by GPRS wireless network connection to Internet, and then passes to middle calculation then by driving GPRS communication module
According to library.The GPRS communication module is remote station GPRS DTU, and DTU connects GPRS network when being switched on automatically, passes through GPRS net
Data timing is sent to the data center of specified database by network, and data center carries out protocol conversion also after receiving the data of DTU
Original subscriber's data, data center can access from Internet.
(4) cloud server cluster includes central database, Web server and data analytics server.Central database will
Receive the data that remote station GPRS DTU is transmitted in the step (3)；Web server will manage and store these information, be convenient for
The inquiry of user；Data analytics server will be analyzed the data of central database by internal software, automatically generate
The analysis reports such as the operating status report of lathe, product energy consumption, efficiency.
(5) reports such as the lathe operating status, product energy consumption, the efficiency that generate in the step (4) are stored in Cloud Server,
Authorized user login system can inquire on computers.It is bent that one side lathe seller technical staff can inquire lathe work
The report such as line, energy consumption, grasps the operating status of lathe at any time, can also further be divided by fault diagnosis module data
Analysis, makes the failure that lathe may occur and timely judges, realizes remote fault diagnosis, and proposes that failure copes with decision；Separately
On the one hand, lathe client can monitor at any time the operating status of product by client software, obtain the bases such as energy consumption, the efficiency of product
This information can also obtain remote fault diagnosis report and failure reply decision etc. from technical staff there.
Using technical solution provided by the invention, compared with prior art, have the advantages that
(1) acquisition platform depends on the industrial embedded system platform based on ARM technology, strong real-time, small in size, power consumption
It is low, it is suitable for industrial environment.
(2) every lathe has independent networked capabilities, does not depend on Client Enterprise Intranet.
(3) data transmission uses GPRS infinite network, avoids the work for being laid with optical fiber, cable, and can be each to being sold to
The lathe on ground is connected to the network, and can be directly with Internet intercommunication, and network transmission speed is high, ensure that the timeliness of data
Property, it realizes the real-time acquisition of data and uploads.
(4) data storage is with processing using Cloud Server, and the difficulty of data management reduces, extension storage space side
Just, data access is convenient, is truly realized long-range monitoring.
Detailed description of the invention
Fig. 1 is the composition block diagram of device involved in method.
Fig. 2 is the information flow chart of system.
Specific embodiment
To further appreciate that the contents of the present invention, the present invention is described in detail in conjunction with the accompanying drawings and embodiments.
In conjunction with attached drawing 1, the embedded system in apparatus of the present invention is using Broadcom BCM2835 700MHz at present
ARM1176JZFS processor, band FPU and Video Core IV double-core GPU；Server end CPU is single Intel Xeon E5-
2400, dual processors are supported；Client CPU is Intel Core i3.
By the operating status of displacement sensor, temperature sensor, current sensor, liquid level sensor and PLC acquisition lathe
Information.It includes the analog quantitys such as spindle motor current, spindle power, temperature that sensor, which mainly acquires, by Machine Tool Electric Appliance circuit and PLC
The acquisition of signaling point obtains the information such as energized state, main shaft start and stop, the coolant liquid switch of lathe；
The working principle of the data transmission module is with the course of work: the interface circuit of embedded system is by above-mentioned sensing
The signal of device and PLC are converted into processor chips by processing appropriate (such as filtering, level conversion, A/D are converted) and are subjected to
Signal, be transmitted to chip BCM2835ARM, then by driving GPRS communication module, by GPRS wireless network connection to
Internet, and then pass to central database.The GPRS communication module is that remote station GPRS DTU, DTU must built-in phases
Processing protocol stack is closed, to complete the interface protocol conversion of user equipment, while must have the function of exception and fault-tolerant processing,
DTU selects CMNET access Internet and data center to carry out data interaction.
Cloud server cluster includes central database, Web server and data analytics server, is mainly responsible for unified management
Data are acquired, it is characterized in that highly distributed, height virtualize, so that Internet resources are fully utilized.Central database
Receive the information that said distal ends station GPRS DTU is transmitted.Data analytics server analyzes data by internal software,
Obtain the analysis reports such as the operating status report of lathe, product energy consumption, efficiency.On the one hand, the technical staff of lathe seller can
The operation report for inquiring lathe understands the operating status of lathe in time, makes to the failure being likely to occur and timely judging, thus
It realizes remote fault diagnosis, and proposes that failure reply decision is supplied to lathe user；On the other hand, the use client Ke Tong of lathe
Access Web server is crossed, the operating status of product is monitored at any time, obtains the essential informations such as energy consumption, the efficiency of product, it can also be from skill
Art personnel there obtains remote fault diagnosis report and failure reply decision etc..
Fig. 2 is the information flow chart of system, and in conjunction with attached drawing 2, the process of this system signal transmitting is: lathe external sensor
With the data of PLC harvester bed operating, the processor chips of embedded system are transferred data to by external circuits, are handled
After device amplifies signal, filters, by communication interface, wireless data terminal is uploaded to.Data terminal passes through GPRS network
Remote data transmission is carried out with mobile network, data are passed into cloud.The software of Cloud Server carries out processing analysis to data, with
Convenient for the inquiry of user.The user of lathe can access cloud data at any time, understand the operation conditions of equipment in time.The dimension of lathe
Shield technical staff can analyze according to the data in cloud, make the decision of fault diagnosis report and reply, be supplied to user.
Claims (1)
1. a kind of information collection of forging machine tool operating condition and analysis system based on technology of Internet of things, which is characterized in that including
Data acquisition module, data transmission module, four modules of data management module and data sharing module, wherein
The data acquisition module: including displacement sensor, temperature sensor, current sensor, liquid level sensor and PLC,
Displacement sensor, temperature sensor, current sensor, liquid level sensor acquire the vibration signal of lathe, lathe work temperature respectively
Degree, machine tool chief axis electric current and hydraulic oil liquid level, PLC are used to acquire the energized state of lathe, main shaft start and stop, coolant liquid switch letter
Breath；
The data transmission module: including embedded system, GPRS DTU (General Packet Radio Service
Data Transfer unit) and mobile network communication, Interface of Embedded System circuit is used for the input/output switching amount of PLC
Signal and displacement sensor, temperature sensor, current sensor, liquid level sensor signal turned by Signal Pretreatment and A/D
Processor chips ARM, the GPRS DTU for sending embedded system to is changed for exchanging information with the external world, signal can be passed through
GSM mobile communication is connected to Internet, and then passes to central database；
The data management module: being realized using cloud server cluster, and cloud server cluster includes central database, Web clothes
Business device and data analytics server for being managed collectively acquisition data, and carry out the analysis processing of data, generation operating status report
Announcement, product energy consumption, Efficiency Analysis Report, to facilitate the inquiry of data and share；
The data sharing module: including personal computer, for the shared of data, the technology people of one side lathe seller
Member can obtain the operating status of lathe according to the analysis of shared data, make to the failure being likely to occur and timely judging, and can
The scheme for proposing product improvement according to this, generates remote fault diagnosis report and conditions of machine tool report is supplied to client；On the other hand
Client can inquire cloud data at any time by personal computer, monitor the operating status of lathe at any time；
The workflow of the system is as follows:
(1) external displacement sensor, temperature sensor, current sensor and liquid level sensor on forging machine tool, utilize displacement
Sensor, temperature sensor, current sensor, liquid level sensor acquire the vibration signal of lathe, lathe operating temperature, machine respectively
Bed spindle motor current and hydraulic oil liquid level；
(2) switching value information is acquired to the signaling point of PLC, by reading the I/O state of PLC, come obtain lathe energized state,
Main shaft start and stop, coolant liquid switching information；
(3) interface circuit of embedded system is by displacement sensor, temperature sensor, electric current in the step (1), step (2)
The signal of sensor, liquid level sensor and PLC is transmitted to the processor core of embedded system by Signal Pretreatment and A/D conversion
The input port of piece ARM by GPRS wireless network connection to Internet, and then is passed to by driving GPRS communication module
Heart database, the GPRS communication module are remote station GPRS DTU, and DTU connects GPRS network when being switched on automatically, passes through
Data timing is sent to the data center of specified database by GPRS network, and data center carries out agreement after receiving the data of DTU
Conversion reduction user data, data center can access from Internet；
(4) cloud server cluster includes central database, Web server and data analytics server, and central database will receive
The data that remote station GPRS DTU is transmitted in the step (3)；Web server will manage and store these information, be convenient for user
Inquiry；Data analytics server will be analyzed the data of central database by internal software, and lathe is automatically generated
Operating status report, product energy consumption, Efficiency Analysis Report；
(5) the lathe operating status of generation, product energy consumption, Efficiency Analysis Report are stored in Cloud Server in the step (4), award
Power user login system can inquire on computers, and it is bent that one side lathe seller technical staff can inquire lathe work
Line, energy consumption report, grasp the operating status of lathe at any time, can also further be divided by fault diagnosis module data
Analysis, makes the failure that lathe may occur and timely judges, realizes remote fault diagnosis, and proposes that failure copes with decision；Separately
On the one hand, lathe client can monitor at any time the operating status of product by personal computer, and energy consumption, the efficiency for obtaining product are basic
Information can also obtain remote fault diagnosis report from the technical staff there of lathe seller and failure copes with decision；
Wherein, embedded system is using Broadcom BCM2835700MHz ARM1176JZFS processor, band FPU and
Video Core IV double-core GPU；Server end CPU is single Intel Xeon E5-2400, supports dual processors；Client CPU
For Intel Core i3；
The running state information of lathe is acquired by displacement sensor, temperature sensor, current sensor, liquid level sensor and PLC,
It includes the analog quantitys such as spindle motor current, spindle power, temperature that sensor, which mainly acquires, by Machine Tool Electric Appliance circuit and PLC signal
The acquisition of point obtains the energized state of lathe, main shaft start and stop, coolant liquid switching information；
The working principle of the data transmission module is with the course of work: the interface circuit of embedded system by the sensor with
The signal of PLC passes through processing appropriate: filtering, level conversion, A/D are converted into the acceptable signal of processor chips, pass
It is sent to chip BCM2835ARM, then by driving GPRS communication module, by GPRS wireless network connection to Internet, in turn
Pass to central database；The GPRS communication module is the necessary built-in relevant treatment protocol stack of remote station GPRS DTU, DTU,
To complete the interface protocol conversion of user equipment, while must have the function of exception and fault-tolerant processing, DTU selection CMNET connects
Enter Internet and data center carries out data interaction；
Cloud server cluster includes central database, Web server and data analytics server, is mainly responsible for unified management acquisition
Data, it is characterized in that highly distributed, height virtualize, so that Internet resources are fully utilized；Central database receives
The information that said distal ends station GPRS DTU is transmitted；Data analytics server analyzes data by internal software, obtains
The operating status report of lathe, product energy consumption, Efficiency Analysis Report；On the one hand, the technical staff of lathe seller can enquiry machine
The operation report of bed understands the operating status of lathe in time, makes to the failure being likely to occur and timely judging, to realize remote
Remote fault diagnosis, and propose that failure reply decision is supplied to lathe user；On the other hand, the use client of lathe can pass through access
Web server, at any time monitor product operating status, obtain energy consumption, the efficiency essential information of product, can also from technical staff that
In obtain remote fault diagnosis report and failure and cope with decision；
The process of this system signal transmitting is: the data of lathe external sensor and PLC harvester bed operating pass through external circuits
The processor chips of embedded system are transferred data to, after processor amplifies signal, filters, by communication interface,
Upload to wireless data terminal；Data terminal carries out remote data transmission by GPRS network and mobile network, and data are passed to
The software in cloud, Cloud Server carries out processing analysis to data, in order to the inquiry of user；The user of lathe can access at any time
Cloud data understand the operation conditions of equipment in time；The maintenance personnel of lathe can analyze according to the data in cloud,
The decision for making fault diagnosis report and reply, is supplied to user；
The information collection of forging machine tool operating condition and analysis system based on technology of Internet of things depend on the work based on ARM technology
Industry embedded system platform, it is strong real-time, small in size, low in energy consumption, it is suitable for industrial environment；
The information collection of forging machine tool operating condition and every lathe of analysis system based on technology of Internet of things have independent networking
Ability does not depend on Client Enterprise Intranet；
The information collection of forging machine tool operating condition and the transmission of analysis system data based on technology of Internet of things are unlimited using GPRS
Network avoids the work for being laid with optical fiber, cable, and can be connected to the network to the lathe for being sold to various regions, and can directly with
Internet intercommunication, increases substantially network transmission speed, ensure that the timeliness of data, realize data it is real-time acquisition with
It uploads；
What the information collection of forging machine tool operating condition and analysis system the data storage based on technology of Internet of things was used with processing
It is Cloud Server, the difficulty of data management reduces, and extension storage space is convenient, and data access is convenient, is truly realized long-range prison
Control.
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