CN111037749B - Fault troubleshooting and alarming system in concrete production process - Google Patents
Fault troubleshooting and alarming system in concrete production process Download PDFInfo
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- CN111037749B CN111037749B CN201911329700.4A CN201911329700A CN111037749B CN 111037749 B CN111037749 B CN 111037749B CN 201911329700 A CN201911329700 A CN 201911329700A CN 111037749 B CN111037749 B CN 111037749B
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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
- B28C7/00—Controlling the operation of apparatus for producing mixtures of clay or cement with other substances; Supplying or proportioning the ingredients for mixing clay or cement with other substances; Discharging the mixture
- B28C7/02—Controlling the operation of the mixing
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B25/00—Alarm systems in which the location of the alarm condition is signalled to a central station, e.g. fire or police telegraphic systems
- G08B25/01—Alarm systems in which the location of the alarm condition is signalled to a central station, e.g. fire or police telegraphic systems characterised by the transmission medium
- G08B25/08—Alarm systems in which the location of the alarm condition is signalled to a central station, e.g. fire or police telegraphic systems characterised by the transmission medium using communication transmission lines
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B7/00—Signalling systems according to more than one of groups G08B3/00 - G08B6/00; Personal calling systems according to more than one of groups G08B3/00 - G08B6/00
- G08B7/06—Signalling systems according to more than one of groups G08B3/00 - G08B6/00; Personal calling systems according to more than one of groups G08B3/00 - G08B6/00 using electric transmission, e.g. involving audible and visible signalling through the use of sound and light sources
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Abstract
The invention discloses a fault troubleshooting and alarming system in the concrete production process, which comprises a detection device, a storage device, an influence factor acquisition device, an intelligent adjusting module and a fault analysis module, wherein the detection device is used for detecting the running state of equipment and material quality parameters and outputting detection data, the storage device is used for storing the incidence relation between the material quality parameters and the faults of each production node at each production node and in a material transmission section, the influence factor acquisition device is used for acquiring the influence factors influencing the incidence relation between the material quality and the faults of each production node, the intelligent adjusting module receives the influence factors and adjusts an incidence probability table based on a set algorithm, the fault analysis module is used for generating and outputting the corresponding fault probability of each production node, when the material quality parameters at one production node are greatly changed, the fault node is rapidly locked according to the probability relation, therefore, the troubleshooting time is shortened, and the production efficiency of the concrete is improved.
Description
Technical Field
The invention relates to the technical field of concrete production monitoring, in particular to a troubleshooting and alarming system in a concrete production process.
Background
The industrial concrete production mainly comprises three steps of feeding, mixing and discharging, wherein each step is subdivided into a plurality of substeps, such as incoming material screening, incoming material storage, incoming material calling and the like. In the production and processing of concrete, the quality of the product is closely related to the accurate implementation of the steps, and the control of the process and the troubleshooting on the production line are the key for ensuring the quality of the concrete product.
In production practice, it is found that factors affecting the quality of a concrete final product are contained in each sub-step but are not completely determined by one of the sub-steps, namely, the level of the concrete production quality is a comprehensive probability superposition event, and when a quality problem occurs in a finished concrete product, it is difficult to know which process step has the problem, namely, a fault site cannot be timely found out, and the generation efficiency of the concrete is affected.
Disclosure of Invention
The invention aims to provide a fault troubleshooting system in a concrete production process, which can quickly lock the fault site in a production line and timely output prompt information, is convenient for quickly removing faults and ensures the production efficiency of concrete. Based on the fault troubleshooting system in the concrete production process, the invention aims to provide a fault alarm system in the concrete production process, and the concrete scheme is as follows:
a concrete production process troubleshooting system comprising:
the detection devices are arranged at the production nodes and in the material transmission section and are used for detecting the running states and material quality parameters of equipment at the production nodes and the material transmission section and correspondingly outputting detection data;
the storage device is configured to be used for storing the association relation between the material quality parameters and the faults of the production nodes at the production nodes and in the material transmission section and generating an association probability table;
the influence factor acquisition device is configured to be used for acquiring influence factors influencing the incidence relation between the material quality and the faults of the production nodes;
the intelligent adjusting module is in data connection with the storage device, receives the influence factors and adjusts the association probability table based on a set algorithm;
the fault analysis module is in signal connection with the detection device, receives the detection data and generates and outputs fault probability corresponding to each production node based on the associated probability table;
and the communication module is configured for data communication among the devices and the modules.
Through the technical scheme, the corresponding probability relation between the material quality parameters and the faults of all production nodes is utilized, when the material quality parameters of a certain production node are changed greatly, the fault node can be locked quickly according to the probability relation, the fault troubleshooting time is shortened, and the production efficiency of concrete is ensured.
Further, the influence factor collecting device includes:
the automatic acquisition terminal is configured to be used for acquiring environmental parameter information in the concrete production process, equipment running state information at each production node or in the material transportation section and corresponding operator information at each production node;
the active input end is configured to be used for collecting incoming material information at a specific production node and parameter modification information of equipment at each production node.
Through the technical scheme, automatic acquisition and active input are combined, and stable and quick acquisition of the influence factors can be realized.
Further, the detection device includes:
the conveying speed detection module is arranged in the conveying belt and/or the spiral feeder and is used for detecting and outputting the material conveying speed;
the stirring speed detection module is arranged on the stirrer and used for detecting the stirring speed of the materials in the stirrer;
the material water content detection module is arranged at a storage bin or a material transportation middle node and is used for detecting and outputting the water content of the material;
and the communication rate detection module is arranged among the communication nodes and is used for detecting and outputting the communication rate among the communication nodes.
Through the technical scheme, potential faults can be detected from the equipment end, the material end and the communication end.
Further, the storage device is configured as a main memory provided in the central control room and a sub memory provided in each detection device, and the main memory and the sub memory are communicatively connected by the communication module.
Furthermore, a timing unit and a communication trigger unit are arranged in the auxiliary memory, and the timing unit is in signal connection with the communication trigger unit;
the communication trigger unit outputs the data information in the secondary memory to the primary memory in response to the timing output signal of the timing unit and the external trigger signal.
Through the technical scheme, the detection data can be prevented from being lost, and the fault node can be traced in the later stage.
Furthermore, the intelligent adjusting module and the fault analyzing module are configured in a cloud server, a central control room or a set mobile communication terminal.
Further, the communication module comprises an internet/WIFI/4G/GPRS communication module.
Through the technical scheme, remote transmission of data information can be realized.
A concrete production process fault alarm system comprising:
the fault probability acquisition module is configured to be in data connection with the fault troubleshooting system in the concrete production process, and receive and acquire the fault probability corresponding to each production node output by the fault analysis module;
the alarm signal triggering module is internally provided with a data arithmetic unit, receives the corresponding fault probability at the production node, compares the fault probability with a set value and outputs an alarm triggering signal if the fault probability exceeds the set value;
the alarm module is configured to be a field acousto-optic alarm module and a remote alarm module, the field acousto-optic alarm module comprises LED lamps and buzzers which are arranged at all production nodes, and the remote alarm module comprises a GPRS communication assembly or an internet communication assembly.
Through the technical scheme, the alarm can be timely output according to the fault probability of each production node, so that the fault node can be quickly locked after the fault occurs, and the fault probability can be reduced to a certain extent.
Further, the alarm system is also provided with:
and the early warning module comprises a temporary memory and an early warning information sending component, is configured to be in data connection with the alarm signal triggering module and the timing unit, receives and stores the operation result of the data operator in each time period, and outputs early warning information to the early warning information sending component if the change times of the data operator in the set time period is greater than a set value.
Through the technical scheme, the early warning can be made before the fault occurs, and the probability of the fault occurrence is reduced.
Further, the alarm system is also provided with:
the system comprises a fault solution information storage module, a fault analysis module and a fault analysis module, wherein the fault solution information storage module is configured to be used for storing each node fault and corresponding solution information thereof;
and the fault solution generation module is configured to be in data connection with a storage device in the fault troubleshooting system in the concrete production process, and search and output fault nodes and corresponding solution information thereof based on the incidence relation between the material quality parameters at the fault nodes and the faults of the production nodes.
Through the technical scheme, when a fault occurs or a fault symptom appears, a method for solving the fault problem is quickly found out, and the production efficiency is favorably improved.
Compared with the prior art, the invention has the following beneficial effects:
by utilizing the corresponding probability relationship between the material quality parameters and the faults at each production node, when the material quality parameters at a certain production node are changed greatly, the fault node is quickly locked according to the probability relationship, so that the fault troubleshooting time is shortened, and the production efficiency of concrete is ensured.
Drawings
FIG. 1 is a general schematic view of a troubleshooting system for a concrete production process of the present invention;
FIG. 2 is an overall schematic diagram of the concrete production process fault alarm system of the present invention.
Reference numerals: 1. a detection device; 2. a storage device; 3. an influence factor acquisition device; 4. an intelligent adjusting module; 5. a fault analysis module; 6. a main memory; 7. a secondary memory; 8. a timing unit; 9. a communication trigger unit; 11. a failure probability obtaining module; 12. an alarm signal triggering module; 13. an alarm module; 14. an early warning module; 15. an automatic acquisition end; 16. an active input terminal.
Detailed Description
The present invention will be described in further detail with reference to examples and drawings, but the present invention is not limited to these examples.
A troubleshooting system for a concrete production process is shown in figure 1 and mainly comprises a detection device 1, a storage device 2, an influence factor acquisition device 3, an intelligent adjustment module 4, a fault analysis module 5 and a communication module for data communication among the devices and the modules.
The detection device 1 is arranged at each production node and in the material conveying section, and is used for detecting the running state and material quality parameters of equipment at each production node and material conveying section and correspondingly outputting detection data.
In practical production, the above-mentioned detection device 1 includes but is not limited to: conveying speed detection module, stirring speed detection module, material water content detection module and communication speed detection module.
The conveying speed detection module is arranged in the conveying belt and/or the spiral feeder and used for detecting and outputting the material conveying speed, and in specific application, the conveying speed detection module can adopt an infrared speed measurement sensor, an ultrasonic speed measurement sensor and the like. The stirring speed detection module is arranged on the stirrer and used for detecting the stirring speed of the material in the stirrer. The stirring speed detection module comprises an infrared speed measurement sensor or a proximity switch and is used for detecting the rotation speed of the stirrer. The material water content detection module is arranged at a middle node of the storage bin or the material transportation, and detects and outputs the water content of the material. The communication rate detection module is arranged among the communication nodes and is used for detecting and outputting the communication rate among the communication nodes.
It should be noted that each of the above-mentioned detecting devices 1 may be performed in a fully automatic manner, and may also include a detection manner involving human labor, for example, the detection of the moisture content of the material may be completed by a humidity sensor, or may be completed by manual sampling.
The storage device 2 is configured to store the association relationship between the material quality parameters and the faults of the production nodes at the production nodes and in the material conveying section, and generate an association probability table. In detail, the storage device 2 is configured as a main memory 6 provided in a central control room and a sub-memory 7 provided in each detection device 1, and the main memory 6 and the sub-memory 7 are communicatively connected by the communication module. In a specific embodiment, the transmission speed detection module is configured as an infrared speed sensor and a microprocessor module connected to the infrared speed sensor, such as a single chip module, and the single chip module is in signal connection with the infrared speed sensor and externally connected to an RAM storage module (secondary memory 7) for receiving and storing an output signal of the infrared speed sensor.
Preferably, the sub-memory 7 incorporates a timer unit 8 and a communication trigger unit 9, and the timer unit 8 is signal-connected to the communication trigger unit 9. In a specific embodiment, the timing unit 8 includes a timer connected to the clock signal of the single chip module, and the timer can be replaced by a counting program, and outputs a timing output signal when the timer reaches a set value. The communication trigger unit 9 outputs the data information in the sub-memory 7 to the main memory 6 in response to the timing output signal of the timing unit 8 and the external trigger signal. The external trigger signal includes, but is not limited to, a data request signal from the central control room. According to the technical scheme, the detection data can be prevented from being lost, and the fault node can be traced in the later stage.
The influence factor collecting device 3 is configured to collect influence factors that influence the correlation between the material quality and the faults of each production node. The above-mentioned influence factors include ambient temperature, humidity, equipment failure rate, material transfer rate, difference between incoming material quality and standard quality, etc.
The influencing factor acquiring means 3 comprises an automatic acquiring terminal 15 and an active input terminal 16. The automatic acquisition terminal 15 is configured to be used for acquiring environmental parameter information in a concrete production process, equipment operation state information at each production node or in a material transportation section, and operator information corresponding to each production node. The active input 16 is configured to collect incoming material information at a particular production node, parameter modification information for equipment at each production node. According to the technical scheme, automatic acquisition and active input are combined, and stable and quick acquisition of the influence factors can be realized.
The intelligent adjustment module 4 is configured to be in data connection with the storage device 2, receive the influence factors, and adjust the association probability table based on a setting algorithm. The fault analysis module 5 is in signal connection with the detection device 1, receives the detection data, and generates and outputs a fault probability corresponding to each production node based on the associated probability table.
In order to realize centralized data processing, the intelligent adjusting module 4 and the fault analyzing module 5 are configured in a cloud server, a central control room or a configured mobile communication terminal.
The communication module comprises an internet/WIFI/4G/GPRS communication module, and remote transmission of data information is achieved.
According to the fault troubleshooting system in the concrete production process, by utilizing the corresponding probability relationship between the material quality parameters and the faults at each production node, when the material quality parameters at a certain production node are changed greatly, the fault node can be locked quickly according to the probability relationship, so that the fault troubleshooting time is shortened, and the production efficiency of concrete is ensured.
Based on the fault troubleshooting system in the concrete production process, the invention also provides a fault alarm system in the concrete production process, which comprises a fault probability acquisition module 11, an alarm signal triggering module 12 and an alarm module 13, as shown in fig. 2.
The failure probability obtaining module 11 is configured to be in data connection with the troubleshooting system in the concrete production process as described above, and receive and obtain the failure probability corresponding to each production node output by the failure analysis module 5. The alarm signal triggering module 12 is internally provided with a data arithmetic unit, receives the corresponding failure probability at the production node, compares the failure probability with a set value, and outputs an alarm triggering signal if the failure probability exceeds the set value. In practical applications, the alarm signal triggering module 12 may be implemented by a dedicated DSP chip or by programming of a microprocessor.
In order to make an early warning before a fault occurs and reduce the probability of the fault occurrence, an early warning module 14 is further arranged in the alarm system. The early warning module 14 includes a temporary storage and an early warning information sending component, and is configured to be in data connection with the alarm signal triggering module 12 and the timing unit 8, receive and store the operation result of the data operator at each time interval, and output early warning information to the early warning information sending component if the number of changes of the data operator within a set time is greater than a set value.
In order to quickly find out a method for solving the fault problem after the fault occurs or fault symptoms appear, a fault solution information storage module and a fault solution generation module are also configured in the alarm system. The fault solution information storage module is configured to store each node fault and its corresponding solution information. The fault solution generation module is configured to be in data connection with the storage device 2 in the fault troubleshooting system in the concrete production process, and based on the incidence relation between the material quality parameters at the fault nodes and the faults of the production nodes, the fault nodes and the corresponding solution information of the fault nodes are searched and output, so that the production efficiency is improved.
The above description is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may occur to those skilled in the art without departing from the principle of the invention, and are considered to be within the scope of the invention.
Claims (10)
1. A concrete production process troubleshooting system characterized by comprising:
the detection device (1) is arranged at each production node and in the material transmission section, is used for detecting the running state and material quality parameters of equipment at each production node and material transmission section, and correspondingly outputs detection data;
the storage device (2) is configured to be used for storing the association relation between the material quality parameters and the faults of the production nodes at the production nodes and in the material transmission section and generating an association probability table;
the influence factor acquisition device (3) is configured to be used for acquiring influence factors influencing the incidence relation between the material quality and the faults of the production nodes;
a smart adjustment module (4) configured to be in data connection with the storage device (2), receive the impact factors, and adjust the associated probability table based on a set algorithm;
the fault analysis module (5) is in signal connection with the detection device (1), receives the detection data and generates and outputs corresponding fault probability at each production node based on the association probability table;
and the communication module is configured for data communication among the devices and the modules.
2. The concrete production process troubleshooting system according to claim 1 wherein said impact factor acquisition means (3) includes:
the automatic acquisition terminal (15) is configured to be used for acquiring environmental parameter information in the concrete production process, equipment running state information at each production node or in a material transportation section and corresponding operator information at each production node;
an active input (16) configured for collecting incoming material information at a particular production node, parameter modification information for equipment at each production node.
3. Concrete production process troubleshooting system according to claim 2 characterized in that said detection means (1) comprises:
the conveying speed detection module is arranged in the conveying belt and/or the spiral feeder and is used for detecting and outputting the material conveying speed;
the stirring speed detection module is arranged on the stirrer and used for detecting the stirring speed of the materials in the stirrer;
the material water content detection module is arranged at a storage bin or a material transportation middle node and is used for detecting and outputting the water content of the material;
and the communication rate detection module is arranged among the communication nodes and is used for detecting and outputting the communication rate among the communication nodes.
4. The concrete production process troubleshooting system according to claim 3, characterized in that said storage means (2) is configured as a primary storage (6) provided in a central control room and a secondary storage (7) provided in each detection means (1), said primary storage (6) and said secondary storage (7) being communicatively connected through said communication module.
5. The concrete production process troubleshooting system according to claim 4 characterized in that a timing unit (8) and a communication trigger unit (9) are built in the sub-memory (7), the timing unit (8) and the communication trigger unit (9) being in signal connection;
the communication trigger unit (9) outputs the data information in the sub memory (7) to the main memory (6) in response to the timing output signal of the timing unit (8) and the external trigger signal.
6. The concrete production process troubleshooting system of claim 2 wherein said intelligent adjusting module (4) and said failure analyzing module (5) are disposed in a cloud server, a central control room or a mobile communication terminal.
7. The concrete production process troubleshooting system of claim 1 wherein said communication module comprises a WIFI/4G/GPRS communication module.
8. A concrete production process fault alarm system, characterized by comprising:
a failure probability obtaining module (11) configured to be connected with the data of the troubleshooting system in the concrete production process according to any one of claims 1-5, and receive and obtain the failure probability corresponding to each production node output by the failure analysis module (5);
the alarm signal triggering module (12) is internally provided with a data arithmetic unit, receives the corresponding fault probability at the production node and compares the fault probability with a set value, and if the fault probability exceeds the set value, an alarm triggering signal is output;
the alarm module (13) is configured to be a field acousto-optic alarm module (13) and a remote alarm module (13), the field acousto-optic alarm module (13) comprises LED lamps and buzzers which are arranged at production nodes, and the remote alarm module (13) comprises a GPRS communication component or an internet communication component.
9. The concrete production process fault alarm system of claim 8, wherein the alarm system is further provided with:
and the early warning module (14) comprises a temporary memory and an early warning information sending component, is configured to be in data connection with the alarm signal triggering module (12) and the timing unit (8), receives and stores the operation result of the data operator in each time period, and outputs early warning information to the early warning information sending component if the change times of the data operator in the set time period is greater than a set value.
10. The concrete production process fault alarm system of claim 8, wherein the alarm system is further configured with:
the system comprises a fault solution information storage module, a fault analysis module and a fault analysis module, wherein the fault solution information storage module is configured to be used for storing each node fault and corresponding solution information thereof;
and the fault solution generation module is configured to be in data connection with a storage device (2) in the fault troubleshooting system in the concrete production process, and is used for searching and outputting fault nodes and corresponding solution information thereof based on the incidence relation between the material quality parameters at the fault nodes and the faults of the production nodes.
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| CN113172764B (en) * | 2021-04-16 | 2023-06-16 | 深圳市艾赛克科技有限公司 | Monitoring method and system for mixing plant |
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| CN202720502U (en) * | 2012-06-28 | 2013-02-06 | 杨人凤 | Dynamic quality remote monitoring system for cement concrete production process |
| CN103770220A (en) * | 2014-02-26 | 2014-05-07 | 徐州徐工施维英机械有限公司 | System and method for positioning fault of stirring station based on material chains and stirring station |
| US10183418B2 (en) * | 2014-04-14 | 2019-01-22 | Verifi Llc | Dynamic segregation monitoring of concrete |
| CN105150383A (en) * | 2015-08-25 | 2015-12-16 | 上海同望信息技术有限公司 | Dynamic monitoring system of production process of cement concrete mixing station |
| CN206627814U (en) * | 2017-03-10 | 2017-11-10 | 江苏理工学院 | Dynamic monitoring system for quality of premixed concrete |
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