CN110319924B - Online fault detection method and system for concrete production equipment based on noise decibels - Google Patents
Online fault detection method and system for concrete production equipment based on noise decibels Download PDFInfo
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- CN110319924B CN110319924B CN201910620867.XA CN201910620867A CN110319924B CN 110319924 B CN110319924 B CN 110319924B CN 201910620867 A CN201910620867 A CN 201910620867A CN 110319924 B CN110319924 B CN 110319924B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 55
- 238000001514 detection method Methods 0.000 title claims abstract description 16
- 230000002159 abnormal effect Effects 0.000 claims abstract description 23
- 238000000034 method Methods 0.000 claims abstract description 11
- 238000005286 illumination Methods 0.000 claims description 9
- 238000009434 installation Methods 0.000 claims description 3
- 230000005856 abnormality Effects 0.000 claims description 2
- 238000012545 processing Methods 0.000 description 15
- 238000004891 communication Methods 0.000 description 9
- 239000000463 material Substances 0.000 description 7
- 238000000605 extraction Methods 0.000 description 5
- 238000005303 weighing Methods 0.000 description 5
- 238000012423 maintenance Methods 0.000 description 4
- 230000032683 aging Effects 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- 230000001133 acceleration Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
- G01H17/00—Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves, not provided for in the preceding groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C9/00—General arrangement or layout of plant
- B28C9/02—General arrangement or layout of plant for producing mixtures of clay or cement with other materials
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F17/00—Digital computing or data processing equipment or methods, specially adapted for specific functions
- G06F17/10—Complex mathematical operations
- G06F17/18—Complex mathematical operations for evaluating statistical data, e.g. average values, frequency distributions, probability functions, regression analysis
Abstract
The invention discloses a concrete production equipment online fault detection method and system based on noise decibels, wherein the detection method comprises the following steps: the method comprises the following steps of firstly, acquiring noise decibel parameter information 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 noise decibels in the running time; step three, comparing the parameter information of noise decibels acquired in real time with the average value obtained by calculation in the step two, and judging whether the parameter has abnormal information or not; 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 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 the generation of factors polluting the environment due to equipment faults from the source and ensure that the relevant requirements of the environment 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 noise decibel-based online fault detection method and system for 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 the on-line fault detection method of the concrete production equipment based on noise decibels, which can automatically judge the potential fault factors of the concrete production equipment and provide data for the timely maintenance of the equipment, thereby ensuring that the production process of the concrete mixing plant meets the relevant requirements of the environmental quality. In addition, the invention also provides an online fault detection system of the concrete production equipment based on noise decibels.
In order to achieve the purpose, the invention adopts the following technical scheme:
the invention provides a concrete production equipment online fault detection method based on noise decibels, which comprises the following steps:
the method comprises the following steps of firstly, acquiring noise decibel parameter information 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 noise decibels in the running time;
step three, comparing the parameter information of noise decibels acquired in real time with the average value obtained by calculation in the step two, and judging whether the parameter has abnormal information 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 parameter information of the noise decibels is larger than the average value of the parameters 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.
As a preferred technical solution, the determining of the failure point in the fourth step includes: if the noise decibel value is larger than the average noise decibel value and the noise decibel value is continuously increased for 3 times, determining that a stirrer bearing, a lining plate, an air cylinder or a feeding door in the concrete production equipment has faults according to the installation position of the noise sensor; taking the value appearing for the first time in the 3 times noise decibel values 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 solution, the first step further comprises the real-time collection of parameter information of temperature, humidity, air pressure and creation strength.
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 concrete production equipment online fault detection system based on noise decibels, which comprises a noise sensor, a parameter reading module, a communication module and a data processing module, wherein the noise sensor is connected with the parameter reading module, the parameter reading module is connected with the data processing module through the communication module, and the noise sensor is arranged on a material weighing layer or a stirring layer of 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, the vibration acceleration, the noise decibel and the current of the main machine of the stirrer, which is 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 each parameter 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 each parameter is 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 submodule and a second parameter comparison submodule, wherein the first parameter comparison submodule is used for comparing real-time parameter information of noise decibels with a corresponding 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 change amplitude of the real-time noise decibel parameter information 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 method can monitor the running condition of the concrete production equipment on line in real time, can automatically identify potential fault factors of corresponding working points of the equipment by taking the noise decibel parameter information 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 the environmental quality are met in the production process of the mixing plant.
Drawings
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 concrete production equipment based on noise decibels according to the present invention.
FIG. 2 is a flow chart of the method for detecting the online fault of the concrete production equipment based on noise decibels according to the present invention.
FIG. 3 is a flow chart of the fault judgment of the online fault detection method for concrete production equipment based on noise decibels according to the present invention.
Wherein the reference numerals are specified as follows: the system comprises a short message issuing module 1, a noise 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 present embodiment provides an on-line detection system for concrete production equipment based on noise decibels, where the concrete production equipment in the present embodiment is a concrete mixing plant, and the on-line detection system includes 4 noise 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 noise sensor 2 is arranged on a material weighing layer or a stirring layer of the concrete mixing plant (specifically arranged on a mixer bearing, a lining plate, a cylinder and a feeding door), 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 plant.
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 noise 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 noise decibel parameter information sent by the parameter reading module 7 and storing the noise decibel parameter information in 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, wherein the first parameter comparison submodule is used for comparing the real-time parameter information of the noise decibels with the corresponding average value, if the real-time parameter value is greater than the average value for 3 times continuously, 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 variation amplitude of the real-time noise decibel parameter information with a preset proportion and judging the fault degree according to the variation 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.
The embodiment provides a concrete production equipment online fault detection method based on noise decibels, which comprises the following steps:
step one, acquiring noise decibel parameter information of different operation points of concrete production equipment in real time through a noise sensor 2.
And step two, after the concrete production equipment runs for a period of time (the running time in the embodiment is 2 days), calculating the average value of the parameter information of noise decibel, temperature, humidity, air pressure and illumination intensity collected in the period of time in the running period of time (the average value refers to the most frequently-occurring value in the running period of time). 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 noise decibels 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 parameter information of the noise decibels is larger than the average value of each parameter, obtaining continuous difference value change and parameter value amplitude change through multiple comparisons, neglecting the sudden change of the value 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 each sensor is continuously greater than the average value of the corresponding parameter 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 each sensor is continuously greater than the average value of the corresponding parameter 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 each sensor is continuously greater than the average value of the corresponding parameter 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 noise decibel value is continuously greater than the average value and the comparison value of the noise decibel for 3 times and the real-time parameter value is continuously increased, determining that the bearing, the lining plate, the cylinder or the feeding door of the mixer in the concrete production equipment has faults according to the installation position of the noise 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 (3)
1. A concrete production equipment online fault detection method based on noise decibels is characterized by comprising the following steps:
the method comprises the following steps of firstly, acquiring noise decibel parameter information 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 noise decibels in the running time;
step three, comparing the parameter information of noise decibels acquired in real time with the average value obtained by calculation in the step two, and judging whether the parameter has abnormal information 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: comparing whether the parameter information of the noise decibels is larger than the average value of the parameters 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;
the judgment of the fault point in the fourth step comprises the following steps: if the noise decibel value is larger than the average noise decibel value and the noise decibel value is continuously increased for 3 times, determining that a stirrer bearing, a lining plate, an air cylinder or a feeding door in the concrete production equipment has faults according to the installation position of the noise sensor; taking the value appearing for the first time in the 3 times noise decibel values 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.
2. The method for detecting the online fault of the concrete production equipment based on the decibels of noise according to claim 1, wherein the first step further comprises the real-time collection of parameter information of temperature, humidity, air pressure and illumination intensity.
3. The method for detecting the online fault of the concrete production equipment based on the decibels of noise according to claim 1, wherein said fourth step further comprises the step of sending the fault information of the concrete equipment to the client terminal.
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| CN201910620867.XA CN110319924B (en) | 2019-07-10 | 2019-07-10 | Online fault detection method and system for concrete production equipment based on noise decibels |
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