CN110542475B - Digital vibration signal intelligent transmitter - Google Patents
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Abstract
The invention provides a digital vibration signal intelligent transmitter, which relates to the technical field of rotating machinery, and comprises a vibration sensor, a signal processing module and a signal processing module, wherein the vibration sensor is used for acquiring and outputting a vibration signal generated by equipment to be tested; the transmitter body is connected with the vibration sensor through a transmission line and is remotely connected with the data analysis center, and the transmitter body comprises a receiving module for receiving vibration signals acquired by the vibration sensor; the processing module is used for processing the vibration signal so as to parameterize the vibration signal and output a parameterization result; the communication module is connected with the processing module and used for sending the parameterization result to the data analysis center for further trend analysis; and the power supply module is used for supplying power to the receiving module, the processing module and the communication module. The method effectively reduces the transmitted data volume, thereby effectively reducing the network bandwidth cost and the cloud data storage cost of the data analysis center, and providing a data production solution for the long-term trend analysis of the vibration signal time domain parameters.
Description
Technical Field
The invention relates to the technical field of rotating machinery, in particular to a digital vibration signal intelligent transmitter.
Background
With the continuous development of modern industry and science and technology, the rotary mechanical equipment is widely applied as key equipment in the fields of electric power, petrochemical industry, aviation and the like as basic equipment used in a large amount in various fields of national economy. Due to the fact that the structure is complex, the rotary mechanical equipment can be operated under severe conditions of high temperature, high speed, fluid-solid coupling and the like for a long time, vibration with abnormal and overlarge amplitude often occurs due to part failure, long-term abrasion and the like, the rotary mechanical equipment can be continuously operated without human intervention, serious failure and shutdown of the rotary mechanical equipment are caused quickly, and serious economic loss and even safety accidents are caused. Therefore, it is a very necessary task to continuously monitor the vibration condition of the operation of the rotating machinery on-line. Along with the increasing of enterprise to the requirement of equipment management and the demand that reduces economic cost, the security and the reliability of rotating mechanical equipment also put forward higher and higher requirement, continuous monitoring data and result that the on-the-spot vibration monitor provided can provide the basis for enterprise and maintainer in time to master the running state of equipment, be favorable to discovering the potential problem of rotating mechanical equipment the very first time to in time maintain and change spare part etc. to equipment, thereby avoid the appearance of serious trouble and prolong rotating mechanical equipment's life greatly.
In the prior art, vibration monitoring and fault diagnosis of mechanical equipment are mainly based on detection and analysis of vibration signals. The basic system comprises the following components: converting the physical quantity of equipment vibration into an electric quantity signal through a sensor arranged on an equipment body; the vibration electric quantity signal is subjected to high-frequency sampling through a high-speed analog/digital conversion card on a computer (a data acquisition workstation and the like), so that the vibration signal is digitized; the collected data is stored locally or transmitted to a database server for storage through a local area network/wide area network; and finally, judging the state trend of the equipment by using methods such as time domain waveform analysis, frequency domain spectrum analysis and the like aiming at the digitized vibration signals, and diagnosing the faults. The typical system is applied to some enterprise-critical rotating mechanical equipment to obtain a good effect. However, such a system has the problems of very high cost, strict requirement on communication transmission, less frequency and dimensionality of data acquisition, insufficient intuition and sufficiency of result parameters of vibration signal data processing, insufficient system expansibility and the like, and cannot be widely popularized and used in enterprises in China.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a digital vibration signal intelligent transmitter, which specifically comprises:
the vibration sensor is arranged at the bearing part of the tested equipment and used for acquiring and outputting a vibration signal generated by the tested equipment;
the changer body, the changer body pass through the transmission line with vibration sensor connects, and a remote connection data analysis center, the changer body includes:
the receiving module is used for receiving the vibration signal acquired by the vibration sensor;
the processing module is connected with the receiving module and used for processing the vibration signal so as to parameterize the vibration signal and output a parameterization result;
the communication module is connected with the processing module and used for sending the parameterization result to the data analysis center for further trend analysis;
and the power supply module is respectively connected with the receiving module, the processing module and the communication module and is used for supplying power to the receiving module, the processing module and the communication module.
Preferably, the transmitter body further includes:
the counting module is connected with the receiving module and used for correspondingly counting when the receiving module receives the vibration signal every time and outputting a counting result;
the self-checking module is connected respectively the count module with power module, the self-checking module specifically includes:
the detection unit is used for detecting whether the counting result changes in real time and outputting a corresponding detection result when the counting result is detected to be unchanged within a preset first time interval;
and the control unit is connected with the detection unit and used for generating a corresponding control instruction according to the detection result so as to control the power supply module to stop supplying power to the receiving module, the processing module and the communication module within a preset second time interval.
Preferably, the transmission line is disposed on a side surface of the transmitter body.
Preferably, the mobile terminal further comprises a communication bus, wherein the communication bus comprises:
the communication module transmits the parameterization result to the data analysis center through the two-core communication line in an RS485 bus communication mode;
the power supply module is connected with an external power supply through the two-core power supply line;
and a bus interface for the communication bus to access is arranged on the side surface of the transmitter body.
Preferably, the two-core communication line transmits the parameterization result to the data analysis center by adopting a MODBUS communication protocol.
Preferably, the vibration signal output by the vibration sensor is an analog signal.
Preferably, the vibration signal output by the vibration sensor is a digital signal, and the data transmission standard for the transmission of the digital signal by the transmission line connecting the vibration sensor and the transmitter body is an IIC transmission protocol or an SPI transmission protocol.
Preferably, the vibration sensor is a MEMS acceleration sensor to perform high frequency sampling on the vibration signal.
Preferably, the processing module is an embedded system of an ARM chip.
Preferably, the processing module specifically includes:
the judging unit is used for outputting a corresponding first judging result when the vibration signal is an analog quantity signal and outputting a corresponding second judging result when the vibration signal is a digital quantity signal;
the analog-to-digital conversion unit is connected with the judgment unit and used for performing analog-to-digital conversion on the vibration signal according to the first judgment result and outputting a corresponding analog-to-digital conversion result;
the preprocessing unit is respectively connected with the judging unit and the analog-to-digital conversion unit and is used for preprocessing the vibration signal according to the second judging result to eliminate a trend item, preprocessing the vibration signal according to the analog-to-digital conversion result to eliminate the trend item and outputting a corresponding preprocessing result;
the first processing unit is connected with the preprocessing unit and used for analyzing the probability density function of the vibration signal according to the preprocessing result to obtain a dimensional value and a dimensionless factor in the time domain waveform of the vibration signal;
the second processing unit is connected with the first processing unit and used for processing the dimensional values and the dimensionless factors to obtain a table with a preset format and using the table as the parameterization result;
the third processing unit is connected with the second processing unit and used for receiving a control instruction issued by the data analysis center and outputting the parameterization result according to a preset third time interval;
the control instruction comprises the preset third time interval.
Preferably, the dimensional values comprise peak values, and/or mean values, and/or root mean square values.
Preferably, the dimensionless factor comprises a form factor, and/or a peak factor, and/or a pulse factor, and/or a margin factor, and/or a kurtosis factor, and/or a skewness factor.
The technical scheme has the following advantages or beneficial effects: by locally completing the acquisition of the vibration signals and simultaneously performing time domain waveform analysis on the acquired vibration signals to parameterize the vibration signals, the transmitted data volume is effectively reduced, so that the network bandwidth cost and the cloud data storage cost of a data analysis center are effectively reduced, and a data production solution is provided for the long-term trend analysis of the vibration signal time domain parameters.
Drawings
Fig. 1 is a schematic system diagram of a digital vibration signal intelligent transmitter according to a preferred embodiment of the present invention.
Detailed Description
The invention is described in detail below with reference to the figures and specific embodiments. The present invention is not limited to the embodiment, and other embodiments may be included in the scope of the present invention as long as the gist of the present invention is satisfied.
In a preferred embodiment of the present invention, based on the above problems in the prior art, there is provided a digital vibration signal intelligent transmitter, as shown in fig. 1, specifically including:
the vibration sensor 1 is arranged at a bearing part of the tested equipment and used for acquiring and outputting a vibration signal generated by the tested equipment;
the receiving module 21 is configured to receive the vibration signal acquired by the vibration sensor;
the processing module 22 is connected with the receiving module 21 and is used for processing the vibration signal to parameterize the vibration signal and outputting a parameterization result;
the communication module 23 is connected with the processing module 22 and is used for sending the parameterization result to the data analysis center for further trend analysis;
and the power supply module 24 is respectively connected with the receiving module 21, the processing module 22 and the communication module 23, and is used for supplying power to the receiving module 21, the processing module 22 and the communication module 23.
Specifically, in this embodiment, the digital vibration signal intelligent transmitter of the present invention is constructed on an industrial internet and a cloud computing platform, and an edge computing architecture is used to locally complete time domain waveform analysis on a vibration signal obtained through acquisition, and then transmit parameterized data after analysis, so as to effectively reduce the amount of transmitted data, thereby effectively reducing network bandwidth cost and cloud data storage cost of a data analysis center. Edge computation is a distributed computing architecture. The edge calculation is to move the calculation of application program, data and service from the network center node to the edge node of the network logic for processing. The edge node is closer to the user terminal device, so that the processing and transmission speed of the data can be increased, and the delay can be reduced. Under the structure, the analysis of the data and the generation of knowledge are closer to the source of the data, so that the data processing method is more suitable for processing large data. The edge calculation solves the actual business of the industrial Internet of things. Processing a large amount of sensor data, namely vibration signals, at the edge can reduce network bandwidth cost and cloud data storage cost. The edge calculation can be used for data analysis and filtration on the transmitter body closer to the vibration sensor, and only the processed information with higher value density can be transmitted to a data analysis center for analysis and storage.
In a preferred embodiment of the present invention, a PCB and an expansion board are disposed inside the transmitter body 2, and the PCB and the expansion board can be disposed in parallel or can be divided into an upper layer and a lower layer. The processing module 22 and the power supply module 24 are integrated on the PCB, and the communication module 23 is integrated on the expansion board.
In another preferred embodiment of the present invention, a main board is disposed inside the transmitter body 2, wherein the processing module 22, the communication module 23 and the power supply module 24 are integrated on the main board.
In a preferred embodiment of the present invention, the transmitter body 2 further includes:
the counting module 25 is connected with the receiving module 21 and is used for correspondingly counting when the receiving module 21 receives the vibration signal every time and outputting a counting result;
self-test module 26 connects count module 25 and power module 24 respectively, and self-test module 26 specifically includes:
the detecting unit 261 is configured to detect whether the counting result changes in real time, and output a corresponding detection result when it is detected that the counting result does not change within a preset first time interval;
and the control unit 262 is connected to the detection unit 261, and is configured to generate a corresponding control instruction according to the detection result, so as to control the power supply module 24 to stop supplying power to the receiving module 21, the processing module 22, and the communication module 23 within a preset second time interval.
Specifically, in this embodiment, when transmitter body 2 normally works, counting module 25 counts correspondingly when receiving module 21 receives the vibration signal each time, and the corresponding counting result is always in a changing state, and when transmitter body 2 works abnormally, counting module 25 stops counting, and the corresponding counting result is unchanged at this time. The counting result of the counting module 25 is detected in real time by the self-detection module 26, whether the transmitter body 2 is in a normal working state is judged through the change of the counting result, if yes, detection is continued, if not, the power supply module 24 is controlled to stop supplying power, a certain second time interval is continued, the receiving module 21, the processing module 22 and the communication module 23 are guaranteed to be powered off and restarted, and normal working can be continued after the transmitter body 2 is restarted. Because the electronic components of each module cannot stop running immediately after power failure, but can be completely powered off after a certain time delay, if the power failure time is too short, each module can still be in an abnormal working state after being restarted, and therefore, a second time interval is preset in the invention to ensure that each module can be restarted after being completely powered off. Preferably, the second time interval is not less than 0.15 seconds.
In the preferred embodiment of the present invention, the transmission line is disposed on the side of the transmitter body 2.
Specifically, in the present embodiment, a transmission line for signal transmission is provided on the side surface of the actuator body 2, and the transmission line realizes connection between the vibration sensor 1 and the actuator body 2 and transmission of the vibration signal.
In a preferred embodiment of the present invention, the present invention further comprises a communication bus, wherein the communication bus comprises:
the communication module 23 transmits the parameterization result to the data analysis center through the two communication lines in an RS485 bus communication mode;
the power supply module 24 is connected to an external power supply through the two-core power supply line;
a bus interface for accessing a communication bus is arranged on the side surface of the transmitter body 2.
In the preferred embodiment of the invention, the two-core communication line adopts MODBUS communication protocol to transmit the parameterization result to the data analysis center.
Specifically, in this embodiment, a bus interface for accessing a communication bus is disposed on a side surface of the variator body 2, the communication bus is preferably a four-core wire, wherein two cores are communication wires, and data transmission between the variator body 2 and the data analysis center 3 is realized by RS485 bus communication; the other two cores are power supply wires and are connected with an external power supply to supply power to the digital vibration signal intelligent transmitter. It should be noted that the use of a quad-core as the communication bus is a preferred embodiment of the present invention, and therefore does not limit the scope of the present invention.
In the preferred embodiment of the present invention, the vibration signal output by the vibration sensor 1 is an analog signal.
In a preferred embodiment of the present invention, the vibration signal output by the vibration sensor 1 is a digital signal, and the data transmission standard used by the transmission line connecting the vibration sensor 1 and the transmitter body 2 for transmitting the digital signal is an IIC transmission protocol or an SPI transmission protocol.
Specifically, in the present embodiment, the vibration sensor 1 may be a digital vibration sensor, or an analog vibration sensor, where the digital vibration sensor outputs a digital quantity signal and the analog vibration sensor outputs an analog quantity signal. When the vibration sensor 1 outputs a digital quantity signal, the data transmission standard used by the transmission line connecting the vibration sensor 1 and the transmitter body 2 may be, but is not limited to, an IIC transmission protocol or an SPI transmission protocol.
In a preferred embodiment of the present invention, the vibration sensor 1 is a MEMS acceleration sensor for high frequency sampling of the vibration signal.
In the preferred embodiment of the present invention, the processing module 22 is an embedded system of an ARM chip.
In a preferred embodiment of the present invention, the processing module 22 specifically includes:
a judging unit 221, configured to output a corresponding first judgment result when the vibration signal is an analog signal, and output a corresponding second judgment result when the vibration signal is a digital signal;
the analog-to-digital conversion unit 222 is connected to the judgment unit 221, and is configured to perform analog-to-digital conversion on the vibration signal according to the first judgment result and output a corresponding analog-to-digital conversion result;
a preprocessing unit 223, respectively connected to the determining unit 221 and the analog-to-digital converting unit 222, for performing data preprocessing on the vibration signal according to the second determination result to eliminate the trend item, and performing data preprocessing on the vibration signal according to the analog-to-digital converting result to eliminate the trend item, and outputting a corresponding preprocessing result;
the first processing unit 224 is connected to the preprocessing unit 223 and configured to analyze the probability density function of the vibration signal according to the preprocessing result to obtain a dimensional value and a dimensionless factor in the time-domain waveform of the vibration signal;
the second processing unit 225 is connected to the first processing unit 224, and is configured to process the dimensional values and the dimensionless factors to obtain a table with a preset format, and use the table as a parameterization result;
the third processing unit 226, connected to the second processing unit 225, is configured to receive the control instruction issued by the data analysis center 3, and output a parameterization result according to a preset third time interval;
the control command includes a preset third time interval.
Specifically, in this embodiment, the output vibration signal may be a digital quantity signal or an analog quantity signal according to the type of the vibration sensor 1, and if the output vibration signal of the vibration sensor 1 is a digital quantity signal, the digital quantity signal is directly preprocessed, and then further processed according to the preprocessing result to obtain a corresponding parameterization result. If the vibration sensor 1 outputs an analog quantity signal, analog-to-digital conversion is required, and the analog quantity signal is processed into a digital quantity signal and then further processed according to the method to obtain a corresponding parameterization result.
In this embodiment, the table with the preset format includes, but is not limited to, a MODBUS address table. The output result of the processing module 22 is sent to the data analysis center 3 in a passive uploading manner, a third time interval is preset in the data analysis center 3, the data analysis center 3 generates a corresponding control instruction according to the third time interval and sends the control instruction to the processing module 22, and the processing module 22 correspondingly sends the output result after receiving the control instruction. A preferred third time interval is 10 seconds.
In a preferred embodiment of the invention, the dimensional values comprise peak values, and/or mean values, and/or root mean square values.
In a preferred embodiment of the invention, the dimensionless factor comprises a form factor, and/or a peak factor, and/or a pulse factor, and/or a margin factor, and/or a kurtosis factor, and/or a skewness factor.
In a preferred embodiment of the present invention, the vibration sensor 1 is connected to the device under test by a rigid connection manner such as bolt connection, and the preferred installation position is a bearing position of the device under test. Preferably, the vibration sensor 1 adopts an MEMS (micro electro mechanical system) acceleration sensor of ADI (adno semiconductor technology limited), a low-energy consumption three-axis measurement with a model of ADXL345, a 13-bit measurement precision, an acceleration range of ± 16g, and a 16-bit binary complement digital output format, and can acquire vibration signals in three directions of X, Y, and Z, thereby realizing high-frequency sampling of up to 3200 samples per second per axis. Preferably, in the embodiment, it is set that vibration acceleration signal data of X, Y, and Z axes are received, and 2048 samples are acquired in each round of each axis.
Further, the processing module 22 integrated on the PCB board built in the transmitter body 2 of the present invention is SAM3X8E model armport-M3 chip of Atmel corporation. The chip SAM3X series has 512KB flash memory and 96KB memory, and the communication module 23 integrated on the expansion board built in the transmitter body 2 of the invention adopts 12V direct current for power supply. And the vibration sensor 1 and the transmitter body 2 adopt four-wire SPI communication.
Further, the processing module 22 integrated on the PCB board built in the transmitter body 2 of the present invention preferably eliminates the trend term of the vibration signal by using the least square method when performing data preprocessing on the vibration signal.
In this embodiment, the dimensional values obtained by analyzing the time domain waveform of the preprocessed vibration signal by the processing module 22 include a peak value, an absolute average value, a root mean square value, and a root mean square amplitude, where the peak value is represented by the following expression:
x+peak＝max(x)x-peak＝min(x)
the absolute average value is expressed by the following expression:
the root mean square value is expressed by the following expression:
the square root amplitude is expressed by the following expression:
in this embodiment, the dimensionless factors obtained by the processing module 22 performing time-domain waveform analysis on the preprocessed vibration signal include a form factor, a peak factor, a pulse factor, a margin factor, a kurtosis factor, and a skewness factor, where the form factor is represented by the following expression:
the crest factor is expressed using the following expression:
the pulse factor is expressed by the following expression:
the margin factor is expressed using the following expression:
the kurtosis factor is expressed using the following expression:
the skewness factor is expressed by the following expression:
in this embodiment, the processing module 22 performs time domain waveform analysis on the preprocessed vibration signal to obtain a dimensional value and a dimensionless factor, and then obtains an MODBUS address table, and uploads the obtained value to the data analysis center 3 through the RS485 bus, and the transmission is preferably set to be once every 10 seconds.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
Claims (11)
1. The utility model provides a digital vibration signal intelligence changer which characterized in that specifically includes:
the vibration sensor is arranged at the bearing part of the tested equipment and used for acquiring and outputting a vibration signal generated by the tested equipment;
the changer body, the changer body pass through the transmission line with vibration sensor connects, and a remote connection data analysis center, the changer body includes:
the receiving module is used for receiving the vibration signal acquired by the vibration sensor;
the processing module is connected with the receiving module and used for processing the vibration signal so as to parameterize the vibration signal and output a parameterization result;
the communication module is connected with the processing module and used for sending the parameterization result to the data analysis center for further trend analysis;
the power supply module is respectively connected with the receiving module, the processing module and the communication module and is used for supplying power to the receiving module, the processing module and the communication module;
the processing module specifically comprises:
the judging unit is used for outputting a corresponding first judging result when the vibration signal is an analog quantity signal and outputting a corresponding second judging result when the vibration signal is a digital quantity signal;
the analog-to-digital conversion unit is connected with the judgment unit and used for performing analog-to-digital conversion on the vibration signal according to the first judgment result and outputting a corresponding analog-to-digital conversion result;
the preprocessing unit is respectively connected with the judging unit and the analog-to-digital conversion unit and is used for preprocessing the vibration signal according to the second judging result to eliminate a trend item, preprocessing the vibration signal according to the analog-to-digital conversion result to eliminate the trend item and outputting a corresponding preprocessing result;
the first processing unit is connected with the preprocessing unit and used for analyzing the probability density function of the vibration signal according to the preprocessing result to obtain a dimensional value and a dimensionless factor in the time domain waveform of the vibration signal;
the second processing unit is connected with the first processing unit and used for processing the dimensional values and the dimensionless factors to obtain a table with a preset format and using the table as the parameterization result;
the third processing unit is connected with the second processing unit and used for receiving a control instruction issued by the data analysis center and outputting the parameterization result according to a preset third time interval;
the control instruction comprises the preset third time interval.
2. The digital vibratory signal intelligent transmitter of claim 1, wherein the transmitter body further comprises:
the counting module is connected with the receiving module and used for correspondingly counting when the receiving module receives the vibration signal every time and outputting a counting result;
the self-checking module is connected respectively the count module with power module, the self-checking module specifically includes:
the detection unit is used for detecting whether the counting result changes in real time and outputting a corresponding detection result when the counting result is detected to be unchanged within a preset first time interval;
and the control unit is connected with the detection unit and used for generating a corresponding control instruction according to the detection result so as to control the power supply module to stop supplying power to the receiving module, the processing module and the communication module within a preset second time interval.
3. The intelligent transmitter of claim 1, wherein the transmission line is disposed on a side of the transmitter body.
4. The digital vibratory signal intelligent transmitter of claim 1 further comprising a communication bus, said communication bus comprising:
the communication module transmits the parameterization result to the data analysis center through the two-core communication line in an RS485 bus communication mode;
the power supply module is connected with an external power supply through the two-core power supply line;
and a bus interface for the communication bus to access is arranged on the side surface of the transmitter body.
5. The intelligent transmitter of claim 4, wherein the two-wire communication line transmits the parameterization result to the data analysis center by using MODBUS communication protocol.
6. The intelligent transmitter of claim 1, wherein the vibration signal output by the vibration sensor is an analog signal.
7. The intelligent transmitter of claim 1, wherein the vibration signal outputted by the vibration sensor is a digital signal, and the transmission line connecting the vibration sensor and the transmitter body transmits the digital signal using a data transmission standard of IIC transmission protocol or SPI transmission protocol.
8. The digital vibration signal intelligent transmitter of claim 7, wherein the vibration sensor is a MEMS acceleration sensor to perform high frequency sampling of the vibration signal.
9. The digital vibratory signal intelligent transmitter of claim 1 wherein the processing module is an embedded system of an ARM chip.
10. The digital vibratory signal intelligent transmitter of claim 9 wherein the dimensional values include peak values, and/or average values, and/or root mean square magnitudes.
11. The digital vibration signal intelligent transmitter of claim 9, wherein the dimensionless factor includes a form factor, and/or a peak factor, and/or a pulse factor, and/or a margin factor, and/or a kurtosis factor, and/or a skewness factor.
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| CN204556098U (en) * | 2015-03-19 | 2015-08-12 | 桂林电子科技大学 | A kind of microseismic signals harvester for the anti-illegal mining monitoring system in colliery |
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| US5984504A (en) * | 1997-06-11 | 1999-11-16 | Westinghouse Electric Company Llc | Safety or protection system employing reflective memory and/or diverse processors and communications |
| CN101752833A (en) * | 2008-12-19 | 2010-06-23 | 上海瑞视仪表电子有限公司 | State monitoring protection device |
| CN201662434U (en) * | 2010-04-03 | 2010-12-01 | 天正集团有限公司 | Intelligent vibration detector based on CAN bus |
| CN202092865U (en) * | 2011-06-22 | 2011-12-28 | 杭州居易电气有限公司 | Measuring instrument for measuring vibration accelerated speed of bearing |
| CN204556098U (en) * | 2015-03-19 | 2015-08-12 | 桂林电子科技大学 | A kind of microseismic signals harvester for the anti-illegal mining monitoring system in colliery |
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