CN110208028B - Online fault detection method and system for concrete production equipment based on dust concentration - Google Patents
Online fault detection method and system for concrete production equipment based on dust concentration Download PDFInfo
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- CN110208028B CN110208028B CN201910620636.9A CN201910620636A CN110208028B CN 110208028 B CN110208028 B CN 110208028B CN 201910620636 A CN201910620636 A CN 201910620636A CN 110208028 B CN110208028 B CN 110208028B
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- 239000000463 material Substances 0.000 claims description 12
- 238000005303 weighing Methods 0.000 claims description 10
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- 230000007613 environmental effect Effects 0.000 abstract description 3
- 238000003912 environmental pollution Methods 0.000 abstract 1
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Abstract
The invention discloses a dust concentration-based on-line fault detection method and a dust concentration-based on-line fault detection system for concrete production equipment, wherein the detection method comprises the following steps: the method comprises the following steps of firstly, acquiring parameter information of dust concentration of different operation points of concrete production equipment in real time; step two, after the concrete production equipment runs for a period of time, respectively calculating the parameter average value of the dust concentration in the running time of the period of time; step three, comparing the parameter information acquired in real time with the average value calculated in the step two, judging whether the parameter has abnormal information, and step four, judging a fault point on the concrete production equipment according to the abnormal information. The invention can monitor the running condition of the concrete production equipment on line in real time, automatically identify potential fault factors of corresponding working points of the equipment, analyze potential fault phenomena, solve environmental pollution caused by equipment faults from the source and ensure that the relevant requirements of environmental quality are met in the production process of the mixing plant.
Description
Technical Field
The invention belongs to the technical field of fault detection of concrete production equipment, and particularly relates to a dust concentration-based on-line fault detection method and system of concrete production equipment.
Background
The concrete production equipment (concrete mixing plant) is an indispensable large-scale equipment in the concrete production process and mainly comprises a mixing host machine, a material weighing system, a material conveying system, a material storage system, a control system and other accessory facilities. In the process of concrete production, along with the aging and the failure of equipment, the production progress can be influenced, and the surrounding environment can also be influenced. For the aging maintenance of concrete production equipment, manual judgment is still used as a reference at present, and because the concrete production equipment is large in size, fault points are difficult to judge accurately in the maintenance process, a large amount of time is often spent, and the production progress is influenced.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides an online fault detection method for concrete production equipment based on dust concentration, which can automatically judge potential fault factors of the concrete production equipment and provide data for timely maintenance of the equipment, thereby ensuring that the production process of a concrete mixing plant meets the relevant requirements of environmental quality. In addition, the invention also provides an online fault detection system of the concrete production equipment based on the dust concentration.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect of the invention, an online fault detection method for concrete production equipment based on dust concentration is provided, which comprises the following steps:
the method comprises the following steps of firstly, acquiring parameter information of dust concentration of different operation points of concrete production equipment in real time;
step two, after the concrete production equipment runs for a period of time, respectively calculating the average value of the dust concentration parameters in the running time of the period of time;
comparing the parameter information of the dust concentration acquired in real time with the average value calculated in the step two, and judging whether abnormal information exists or not;
and step four, judging a fault point on the concrete production equipment according to the abnormal information.
As a preferable technical scheme, in the second step, when the parameter information is collected to calculate the average value, the running time of the concrete production equipment is more than or equal to 48 hours.
As a preferred technical solution, the comparison process in the third step is as follows: and comparing whether the real-time parameter value of the dust concentration is larger than the average value or not, obtaining continuous difference value change and parameter value amplitude change through multiple comparisons, neglecting the numerical value sudden change which is generated once at a time, and obtaining an abnormal information judgment result according to the difference value change and the amplitude change.
As a preferred technical solution, the information judgment result includes abnormality, severity, and extreme severity.
As a preferred technical solution, the determining of the failure point in the fourth step includes: if the dust concentration value is larger than the average value of the dust concentration and the dust concentration value is continuously increased for 3 times, determining that the seal of a weighing hopper or a stirrer in the concrete production equipment is damaged according to the installation position of the dust sensor; taking the value appearing for the first time in the dust concentration values of 3 times as a comparison value, and recording the comparison value into a database server; if the variation amplitude between the maximum value and the minimum value in the 3-time values is less than 30%, the judgment result is abnormal, if the variation amplitude between the maximum value and the minimum value in the 3-time values is between 30% and 50%, the judgment result is serious, and if the variation amplitude between the maximum value and the minimum value in the 3-time values is more than 50%, the judgment result is serious.
As a preferred technical scheme, the first step further comprises the real-time acquisition of parameter information of temperature, humidity, air pressure and illumination intensity.
As a preferable technical solution, the fourth step further includes a step of sending the failure information of the concrete equipment to the client terminal.
The invention provides a dust concentration-based online fault detection system for concrete production equipment, which comprises at least 2 dust sensors, a parameter reading module, a communication module and a data processing module, wherein the dust sensors are connected with the parameter reading module, the parameter reading module is connected with the data processing module through the communication module, and the dust sensors are arranged on a material weighing layer and a material waiting layer of the concrete production equipment.
As a preferred technical solution, the communication module is a wireless communication module with a frequency of 433 mhz.
As a preferred technical scheme, the parameter reading module is an ARM chip module.
As a preferred technical solution, the data processing module includes:
the parameter receiving module is used for receiving the parameter information of the dust concentration sent by the parameter reading module and storing the parameter information to the database server;
the parameter calculation module is used for processing the parameter information acquired after the concrete production equipment operates for a period of time, calculating the average value and the comparison value of the parameters, and storing the average value and the comparison value to the database server;
the parameter comparison module is used for comparing the parameters of the parameter receiving module with the data between the parameter comparison modules so as to judge whether the parameters are abnormal or not;
the parameter extraction module is used for extracting abnormal parameters obtained by comparison in the parameter judgment module;
and the fault positioning module is used for determining a fault point on the concrete production equipment according to the parameters extracted by the parameter extraction module.
As a preferred technical scheme, the parameter comparison module comprises a first parameter comparison module and a second parameter comparison module, the first parameter comparison module is used for comparing the real-time dust concentration with the average value, and if the real-time parameter value is continuously larger than the average value, the parameter is abnormal; the second parameter comparison submodule is used for comparing the real-time change amplitude of the dust concentration with a preset proportion, and if the change amplitude of the parameter information is continuously larger than the preset proportion, the parameter is abnormal.
As a preferred technical scheme, the concrete production equipment further comprises a temperature sensor, a humidity sensor, an air pressure sensor and an illumination sensor, wherein the temperature sensor, the humidity sensor, the air pressure sensor and the illumination sensor are arranged on a material weighing layer of the concrete production equipment.
The system comprises a data processing module, a web service module and a short message issuing module, wherein the data processing module is connected with the web service module and the short message issuing module, and the web service module runs in an IIS server.
Compared with the prior art, the invention has the beneficial effects that: the invention can monitor the running condition of concrete production equipment on line in real time, can automatically identify potential fault factors of corresponding working points of the equipment by taking the parameter information of dust concentration as a reference, analyzes potential fault phenomena, provides data for timely maintenance of the equipment, reduces the fault rate of the concrete equipment, and ensures that the relevant requirements of environmental quality are met in the production process of the mixing plant.
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In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic structural diagram of an online fault detection system of a concrete production facility based on dust concentration.
FIG. 2 is a flow chart of the method for detecting the online fault of the concrete production equipment based on the dust concentration.
FIG. 3 is a flow chart of fault judgment in the online fault detection method for the concrete production equipment based on dust concentration.
Wherein the reference numerals are specified as follows: the system comprises a short message issuing module 1, a dust sensor 2, a web service module 3, a database server 4, a temperature sensor 5, a humidity sensor 6, a parameter reading module 7, a first ARM chip module 8, a second ARM chip module 9, a data processing module 10, an air pressure sensor 11 and an illumination sensor 12.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
As shown in fig. 1, the embodiment provides an online detection system for a concrete production facility based on dust concentration, the concrete production facility referred to in the embodiment is a concrete mixing plant, and the online detection system includes 2 dust sensors 2, 1 temperature sensor 5, 1 humidity sensor 6, 1 barometric pressure sensor 11, 1 illumination sensor 12, a parameter reading module 7, a data processing module 10, a communication module, a web service module 3, and a short message publishing module 1. The 2 dust sensors 2 are respectively arranged on a material weighing layer and a material waiting layer of the concrete mixing station, and the temperature sensor 5, the humidity sensor 6, the air pressure sensor 11 and the illumination sensor 12 are arranged on the material weighing layer of the concrete mixing station.
The parameter reading module 7 comprises a first ARM chip module 8 and a second ARM chip module 9, and the first ARM chip module 8 is used for reading the parameter value of the dust sensor 2. The second ARM chip module 9 is used for reading parameter values of the temperature sensor 5, the humidity sensor 6, the air pressure sensor 11 and the illumination sensor 12. The first ARM chip module 8 and the second ARM chip module 9 are in communication connection with the data processing module 10 through communication modules, and the wireless communication module with the frequency of 433mhz is selected as the communication module. The data processing module 10 runs on a PC acquisition terminal, and the data processing module 10 comprises a parameter receiving module, a parameter comparison module, a parameter extraction module and a fault positioning module.
And the parameter receiving module is used for receiving the parameter information of the dust concentration sent by the parameter reading module 7 and storing the parameter information to the database server 4.
And the parameter calculation module is used for processing the parameter information acquired after the concrete production equipment operates for a period of time, calculating the average value and the comparison value of the parameters, and storing the average value and the comparison value into the database server 4.
And the parameter comparison module is used for comparing the parameter information of the parameter receiving module with the data between the parameter comparison modules so as to judge whether the parameters are abnormal or not. The parameter comparison module comprises a first parameter comparison submodule and a second parameter comparison submodule, the first parameter comparison submodule is used for comparing the real-time dust concentration with the average value, if the real-time parameter value is continuously greater than the average value for 3 times, the parameter is abnormal, the value appearing for the first time in the 3 times of values is taken as a comparison value, and the comparison value is recorded into the database server 4; and the second parameter comparison submodule is used for comparing the real-time change amplitude of the dust concentration with a preset proportion and judging the fault degree according to the change amplitude, wherein the fault degree is divided into abnormity, severity and very severity.
And the parameter extraction module is used for extracting the abnormal parameters obtained by comparison in the parameter judgment module.
And the fault positioning module is used for determining a fault point on the concrete production equipment according to the parameters extracted by the parameter extraction module.
The web service module 3 and the short message issuing module 1 are both connected with the data processing module 10, and the web service module 3 runs in an IIS server. When the data processing module 10 judges that the fault of a certain working point of the concrete mixing plant is very serious, fault information is issued through a computer terminal, a mobile phone APP and a mobile phone short message, and a user is reminded to start an early warning measure and a measure for preventing and treating a pollution source.
As shown in fig. 2 and fig. 3, the embodiment provides an online fault detection method for a concrete production facility based on dust concentration, which includes the following steps:
the method comprises the steps of firstly, acquiring parameter information of dust concentration, temperature, humidity, air pressure and illumination intensity of different operation points of concrete production equipment in real time through a dust sensor 2, a temperature sensor 5, a humidity sensor 6, an air pressure sensor 11 and an illumination sensor 12.
Step two, after the concrete production equipment is operated for a period of time (the operation time in the embodiment is 2 days), respectively calculating the average value of the dust concentration collected in the period of time (the average value refers to the value which is most frequently appeared in the operation time period). The parameter information of temperature, humidity, air pressure and illumination intensity is used for monitoring the working environment of the mixing plant and correcting data during fault judgment.
And step three, comparing the parameter information of the dust concentration acquired in real time with the average value of each parameter calculated in the step two, and judging whether each parameter has abnormal information. And comparing whether the dust concentration is greater than the average value, obtaining continuous difference value change and parameter value amplitude change through multiple comparisons, neglecting the sudden numerical value change generated once at a time, and obtaining an abnormal information judgment result. According to the magnitude of the difference value change and the magnitude of the parameter value amplitude change, dividing the abnormal information judgment structure into abnormal, serious and very serious, specifically, if the real-time parameter value of the sensor is continuously greater than the average value of the parameters for 3 times and the real-time parameter value is continuously increased, if the change amplitude between the maximum value and the minimum value in the 3 times of values is less than 30%, judging that the result is abnormal, and taking the value appearing for the first time in the 3 times of values as a comparison value to be recorded into the database server 4; if the real-time parameter value of the sensor is continuously greater than the average value of the parameters for 3 times and the real-time parameter value is increased, if the variation amplitude between the maximum value and the minimum value in the 3-time values is between 30% and 50%, the judgment result is serious, and the value appearing for the first time in the 3-time values is taken as a comparison value and is recorded into the database server 4; if the real-time parameter value of the sensor is continuously greater than the average value of the parameters for 3 times and the real-time parameter value is increased, if the variation amplitude between the maximum value and the minimum value in the 3-time values is greater than 50%, the judgment result is very serious, and the value appearing for the first time in the 3-time values is taken as a comparison value and is recorded into the database server 4.
And step four, judging a fault point on the concrete production equipment according to the abnormal information. And if the dust concentration value is continuously greater than the average value of the dust concentration for 3 times and the real-time parameter value is continuously increased, determining that the seal of the weighing hopper or the stirrer in the concrete production equipment is damaged according to the installation position of the dust sensor 2.
And step five, sending the fault information of the concrete equipment to a client terminal. When the data processing module 10 judges that the fault of a certain working point of the concrete mixing plant is very serious, fault information is issued through a computer terminal, a mobile phone APP and a mobile phone short message, and a user is reminded to start an early warning measure and a measure for preventing and treating a pollution source.
Although the present invention has been described in detail with respect to the above embodiments, it will be understood by those skilled in the art that modifications or improvements based on the disclosure of the present invention may be made without departing from the spirit and scope of the invention, and these modifications and improvements are within the spirit and scope of the invention.
Claims (10)
1. A method for detecting online faults of concrete production equipment based on dust concentration is characterized by comprising the following steps:
the method comprises the following steps of firstly, acquiring parameter information of dust concentration of different operation points of concrete production equipment in real time;
step two, after the concrete production equipment runs for a period of time, respectively calculating the average value of the dust concentration parameters in the running time of the period of time;
comparing the parameter information of the dust concentration acquired in real time with the average value calculated in the step two, and judging whether abnormal information exists or not;
judging a fault point on the concrete production equipment according to the abnormal information;
in the second step, when parameter information is collected for average value calculation, the running time of the concrete production equipment is more than or equal to 48 hours;
the comparison process of the third step is as follows: and comparing whether the real-time parameter value of the dust concentration is larger than the average value or not, obtaining continuous difference value change and parameter value amplitude change through multiple comparisons, neglecting the numerical value sudden change which is generated once at a time, and obtaining an abnormal information judgment result according to the difference value change and the amplitude change, wherein the information judgment result comprises abnormality, severity and very severity.
2. The online fault detection method for the concrete production equipment based on the dust concentration as claimed in claim 1, wherein the judgment of the fault point in the fourth step comprises:
if the dust concentration value is larger than the average value of the dust concentration and the dust concentration value is continuously increased for 3 times, determining that the seal of a weighing hopper or a stirrer in the concrete production equipment is damaged according to the installation position of the dust sensor; taking the value appearing for the first time in the dust concentration values of 3 times as a comparison value, and recording the comparison value into a database server; if the variation amplitude between the maximum value and the minimum value in the 3-time values is less than 30%, the judgment result is abnormal, if the variation amplitude between the maximum value and the minimum value in the 3-time values is between 30% and 50%, the judgment result is serious, and if the variation amplitude between the maximum value and the minimum value in the 3-time values is more than 50%, the judgment result is serious.
3. The dust concentration-based on-line fault detection method for the concrete production equipment as claimed in claim 1, wherein the first step further comprises the real-time collection of parameter information of temperature, humidity, air pressure and illumination intensity.
4. The dust concentration-based concrete production equipment online fault detection method according to claim 1, wherein the fourth step further comprises a step of sending fault information of the concrete equipment to a client terminal.
5. The online fault detection system for the concrete production equipment based on the dust concentration is characterized by comprising at least 2 dust sensors, a parameter reading module, a communication module and a data processing module, wherein the dust sensors are connected with the parameter reading module, the parameter reading module is connected with the data processing module through the communication module, and the dust sensors are arranged on a material weighing layer and a material waiting layer of the concrete production equipment;
the data processing module comprises:
the parameter receiving module is used for receiving the parameter information of the dust concentration sent by the parameter reading module and storing the parameter information to the database server;
the parameter calculation module is used for processing the parameter information acquired after the concrete production equipment operates for a period of time, calculating the average value and the comparison value of the parameters, and storing the average value and the comparison value to the database server;
the parameter comparison module is used for comparing the parameters of the parameter receiving module with the data between the parameter comparison modules so as to judge whether the parameters are abnormal or not;
the parameter extraction module is used for extracting abnormal parameters obtained by comparison in the parameter judgment module;
and the fault positioning module is used for determining a fault point on the concrete production equipment according to the parameters extracted by the parameter extraction module.
6. The dust concentration-based on-line fault detection system for the concrete production equipment as claimed in claim 5, wherein the communication module is a wireless communication module with a frequency of 433 mhz.
7. The dust concentration-based on-line fault detection system for the concrete production equipment as claimed in claim 5, wherein the parameter reading module is an ARM chip module.
8. The dust concentration-based on-line fault detection system for the concrete production equipment as claimed in claim 7, wherein the parameter comparison module comprises a first parameter comparison submodule and a second parameter comparison submodule, the first parameter comparison submodule is used for comparing the real-time dust concentration with the average value, and if the real-time parameter value is continuously larger than the average value, the parameter is abnormal; the second parameter comparison submodule is used for comparing the real-time change amplitude of the dust concentration with a preset proportion, and if the change amplitude of the parameter information is continuously larger than the preset proportion, the parameter is abnormal.
9. The dust concentration-based concrete production equipment online fault detection system of claim 5, further comprising a temperature sensor, a humidity sensor, an air pressure sensor and an illumination sensor, wherein the temperature sensor, the humidity sensor, the air pressure sensor and the illumination sensor are mounted on a material weighing layer of the concrete production equipment.
10. The dust concentration-based on-line fault detection system for concrete production equipment as claimed in claim 5, further comprising a web service module and a short message issuing module, wherein the web service module and the short message issuing module are both connected with the data processing module, and the web service module runs on an IIS server.
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| CN114978955A (en) * | 2022-04-13 | 2022-08-30 | 杭州悟川科技有限公司 | Industrial equipment health monitoring system based on Internet of things |
| CN117324148B (en) * | 2023-12-01 | 2024-03-15 | 睢宁县泰宁建材有限公司 | Intelligent dust monitoring system for concrete production site |
| CN118940916A (en) * | 2024-10-11 | 2024-11-12 | 江苏中欧化肥有限公司 | Real-time dust monitoring system and control method for fertilizer production |
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| CN102170464B (en) * | 2011-03-17 | 2014-03-19 | 中铁二局股份有限公司 | Dynamic monitoring system method of production process of concrete mixing station |
| CN103728150B (en) * | 2014-01-17 | 2016-08-17 | 徐州徐工施维英机械有限公司 | The fault detection system of a kind of concrete mixing plant and method |
| CN103901878B (en) * | 2014-03-26 | 2016-08-24 | 山推建友机械股份有限公司 | A kind of concrete mixing plant remote failure diagnosis system and method |
| CN107065733A (en) * | 2017-06-05 | 2017-08-18 | 合肥市闵葵电力工程有限公司 | A kind of construction site monitoring system |
| CN108748694A (en) * | 2018-06-22 | 2018-11-06 | 成都精准混凝土有限公司 | A kind of concrete mixing plant system and its operation method |
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