CN111175064B - Method for detecting capacity of computing equipment through noise of acquisition equipment - Google Patents
Method for detecting capacity of computing equipment through noise of acquisition equipment Download PDFInfo
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- CN111175064B CN111175064B CN202010063243.5A CN202010063243A CN111175064B CN 111175064 B CN111175064 B CN 111175064B CN 202010063243 A CN202010063243 A CN 202010063243A CN 111175064 B CN111175064 B CN 111175064B
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Abstract
The invention relates to the field of intelligent detection of equipment, and discloses a detection method for calculating equipment productivity by acquiring equipment noise, which comprises the following steps: acquiring a volume change curve of the high-noise auxiliary machine in operation and defining the volume change curve as a noise curve; the noise curve is subjected to data analysis, the equipment state is calculated from the equipment noise volume, the equipment state change record is calculated from the equipment state, the production period is calculated from the equipment state change record, the previous production beat is calculated from the production period, and the process stability is calculated from the previous production beat. When the machine networking is implemented, the communication work with equipment manufacturers is omitted, and only the equipment power supply cabinet is needed to be connected, and the equipment electric control cabinet is mastered by a customer (an equipment user), so that the communication cost is greatly reduced.
Description
Technical Field
The invention relates to an intelligent detection method for equipment, in particular to a detection method for calculating the productivity of the equipment by acquiring the noise of the equipment.
Background
At present, the 'industrial intelligent networking' is in the initial development stage in China, although the industry is not yet developed, the competition is in a state of being white and hot, and the product construction such as 'industrial intelligent networking platform' is developed even by pure Internet companies.
The promotion of the construction of the industrial intelligent network is to realize the upgrade of the industry of China, and becomes one of means of strengthening the country of the manufacturing industry, and the government supports the related industry. All local enterprises with a certain scale compete for the project declaration of an ideational model of 'intelligent workshop', 'intelligent production line' and 'intelligent factory', and are all used for upgrading and modifying the manufacturing industry. The method is an industry with good market prospect.
"machine networking" is one of the cut-ins of "industry intelligence networking": production data in the machines are collected by connecting production-related machines in a factory through a network, so that the progress of the production process is monitored in real time. "machine networking" is the underlying foundation of "industrial intelligence networking".
In the implementation process of the 'machine networking' work, there are many technical implementation modes, mainly including:
1. for large high-precision equipment produced in recent 5 years, a special data acquisition interface of butt joint equipment can be directly connected by a network cable network, and the data acquisition interface is an OPC communication protocol. The method is an international industrial standard which is widely applied to the field of data acquisition of related equipment of automatic control and instrument and meter process control. The data acquisition mode is common in the industries of injection molding, blow molding and the like.
2. For large-scale high-precision equipment produced 5 years ago, an OPC communication protocol is not arranged inside the equipment, and data acquisition can be carried out in a file reading and writing mode. The method comprises the steps of modifying configuration parameters of equipment, commanding the equipment to store a log file in a certain path in a file management system of the equipment in the processing process, and reading the log by using 'machine networking' software in a network cable connection mode, so as to obtain production and processing data of the equipment.
3. For a medium-sized general precision device, if a PLC (programmable logic controller) is used inside the device, the device data can be collected by reading the data inside the PLC. Most nonstandard automation equipment in China adopts PLC as a core control element.
4. For numerical control machine tool equipment, special data communication can be performed through network cables or serial port cables aiming at control systems of various manufacturers. Common numerical control machine tool control systems are provided with own external data communication protocols, and developers in the networking industry can collect data according to different numerical control protocols.
5. For older equipment without a PLC (programmable logic controller), if the equipment has a three-color lamp, basic state change signals of the equipment can be collected by connecting the three-color lamp.
The above are the five most common "machine networking" working embodiments, but the following problems still exist:
1. the disadvantage of collecting data based on the "OPC" protocol is that some devices or machine tools supporting the "OPC" protocol do not default to open the "OPC" protocol, and the user needs to pay for purchase to open the function. If the equipment is imported equipment with the value of tens of millions, the authorization operation of opening the OPC communication protocol needs to pay high cost, and high cost burden is brought to enterprises. This is therefore a relatively expensive and time-consuming way of communicating implementation.
2. Based on the defect of 'reading and writing files' of collected data, people on the equipment side are required to modify internal parameters of the equipment according to the requirements of the computer networking implementers, so that log files are periodically output to a certain folder. The "person on the device side" may be the device manufacturer itself or a distributor. The method is also an implementation scheme which is time-consuming in communication implementation, high in cost (equipment manufacturers need to modify the equipment) and has certain potential safety hazards; since these devices are generally old, they have some defects, and if some slight functional modification is performed on them, other failures may be caused, and then all the problems may be blamed for the implementation side of the internet of machines. This is therefore a cumbersome, risky, less flexible way of implementation.
3. Based on the defects of data acquisition of the PLC, the PLC (programmable logic controller) is used as a core processing module of the equipment, and non-equipment businessman personnel private line is not allowed, otherwise equipment faults are easily generated. The operator of the 'machine networking' must communicate with the equipment provider, and the operator personnel must be guided on site to connect the line when the line is connected on site. In addition, the "internet of machines" implementer needs to obtain a document such as a "PLC internal variable address table" from the equipment provider, and collect corresponding data according to the address content. This is therefore a highly equipment-dependent and cumbersome way of implementing on site.
4. Based on the defect of data acquisition of a numerical control machine control system, a set of special control program and a corresponding data acquisition protocol are arranged in CNC equipment (numerical control machine tool). Some CNC manufacturers have data acquisition protocols which are open to the outside, and can acquire data only by obtaining the consent of a customer (equipment user) and disconnecting a control panel of a machine tool to be connected with one line under the condition that the equipment manufacturer is not needed to be on site. This type of collection is therefore a type of collection that requires disassembly of the equipment panels and minor modifications to the equipment wiring.
5. Based on the defect that the signal of the equipment is collected by a three-color lamp (equipment warning lamp), the data collection quantity of the mode is a little bit less: only the state change of the device can be collected. The equipment state mainly comes from the equipment state that can gather on the tricolor lamp: and processing, standby and alarming. This type of collection is therefore a way of collecting limited plant data and still requiring plant wiring modifications.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides the detection method for calculating the capacity of the equipment by collecting the noise of the equipment, and the capacity of the equipment can be calculated under the conditions that an equipment control circuit is not changed and the intervention of an equipment manufacturer is not needed.
In order to solve the technical problem, the invention is solved by the following technical scheme:
a method for detecting the production energy of a computing device by collecting the noise of the device comprises the following steps:
step one, collecting the on-site volume of the equipment, and storing data to obtain a volume change curve graph taking time t as an abscissa and volume intensity f (t) as an ordinate;
step two, acquiring a volume change curve of the high-noise auxiliary machine in operation and defining the volume change curve as a noise curve;
and step three, carrying out data analysis on the noise curve, calculating the equipment state from the equipment noise volume, calculating the equipment state change record from the equipment state, calculating the production period from the equipment state change record, calculating the previous production beat from the production period, and calculating the process stability from the previous production beat.
Preferably, if the point set of the device state change record in the noise graph is defined as S:
preferably, the yield of the plant is defined as S', then:
s' ═ β × S, where β is the equipment processing coefficient.
Preferably, when a set of points defining a tact time of past processing is T:
T＝{Ti|Ti＝Si+1-Si}。
preferably, defining the process stability as σ, then:
preferably, the collected volume intensity is compared with a volume threshold in real time, and if the volume intensity is higher than the volume threshold, an alarm is given through a short message.
Due to the adoption of the technical scheme, the invention has the remarkable technical effects that:
1. the field implementation difficulty of the 'machine networking' system is reduced, and meanwhile, the wiring work in the traditional 'machine networking' implementation process is avoided;
2. when the machine networking is implemented, the communication work with equipment suppliers is avoided, and only the equipment power supply cabinet is needed to be connected, and the equipment electric control cabinet is mastered by a customer (an equipment user), so that the communication cost is greatly reduced;
3. the authorization fee or technical support fee is reduced when the machine networking is implemented;
4. the implementation of the 'machine networking' does not need to master the direct source of the basic data (the basic data source is mastered in the hands of the equipment manufacturer, which is an uncontrollable risk, and once the basic data source is not consistent with the equipment manufacturer, the equipment manufacturer can directly cut off the data source), thereby reducing the uncontrollable property in the implementation process of the 'machine networking'.
Drawings
Fig. 1 is a graph of volume change between the volume intensity f (t) and the time t of the on-site acquisition in the present embodiment;
fig. 2 is a graph showing the change of the volume when the high-noise auxiliary engine operates in the present embodiment;
fig. 3 is a system architecture diagram of the present embodiment.
The names of the parts indicated by the numerical references in the above figures are as follows: 1. a noise collector; 2. an equipment end acquisition box; 3. a production line at a workshop end is large-sized; 4. a server; 5. a control module; 6. a touch display module; 7. a WiFi module; 8. a wireless routing module; 9. an industrial personal computer; 10. produce the line large-size screen.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples.
The embodiment discloses a method for detecting the production capacity of computing equipment by acquiring the noise of the equipment, which comprises the following steps:
step one, collecting the on-site volume of the equipment, and storing data to obtain a volume change curve graph taking time t as an abscissa and volume intensity f (t) as an ordinate;
step two, acquiring a volume change curve when the high-noise auxiliary machine operates and defining the volume change curve as a noise curve;
and step three, carrying out data analysis on the noise curve, calculating the equipment state from the equipment noise volume, calculating the equipment state change record from the equipment state, calculating the production period from the equipment state change record, calculating the previous production beat from the production period, and calculating the process stability from the previous production beat.
In the embodiment, taking the field of processing and manufacturing solid wood furniture and panel furniture as an example, most of the procedures are accompanied by strong noise, and mainly include: sawing, punching and tenoning, grinding, planing and the like. By installing a volume collector at the processing position of the processing equipment to collect the volume of the equipment on site and storing data, a volume change curve graph with time t as abscissa and volume intensity f (t) as ordinate can be obtained, as shown in fig. 1.
As can be seen from fig. 1, the volume change curve at the lower left corner differs from the volume change curve at the upper right corner because an auxiliary machine (air compressor) is turned on at the workshop site, so that the volume intensity at the site is increased. At this time, the upper right-hand sound volume change curve is obtained to obtain a noise curve when the high-noise auxiliary machine operates, as shown in fig. 2.
In fig. 2, the peak point of the curve corresponds to the highest noise of the auxiliary machine during the machining process; the valley point of the curve corresponds to the noise low point of the auxiliary machine in the processing process; the curve amplitude corresponds to the noise difference of the auxiliary machine between the processing process and the standby process; the curve wavelength corresponds to the production beat of the auxiliary machine in the processing process. Therefore, by counting the number of peaks of the curve, the number of "production-standby" changes of the equipment, i.e. the processing completion record, i.e. the capacity of the equipment for a certain period of time, can be calculated.
The curve in fig. 2 is similar to a square wave, and the peak duration in this figure corresponds to the duration of the auxiliary machine when processing a single workpiece (product); the valley duration corresponds to the time used by the operator when changing the workpiece (product). The time difference between two peaks, therefore, represents one processing cycle. It can be seen that the machining cycles are different from time to time. The process stability of the equipment, or the proficiency of the operator, can be represented by calculating the variance of the previous processing cycles in a certain time period, namely the difference value of the previous processing cycles. The smaller the variance, the more stable the time taken for the past production process, the more skilled the operator, and the less skilled the operator.
In this embodiment, if the point set of the device state change record in the noise graph is defined as S, then:
defining the yield of the equipment as S', then:
and the beta is the equipment processing coefficient, and because some products need to be processed for multiple times and some products only need to be processed once, the beta can be adjusted according to the processing characteristics of the actual products. For example, in the wood furniture industry, a single-key processing is basically performed on a product by one device, so that the coefficient beta is usually set to be 1; for another example, in the hardware industry, such as semi-automatic lathe machining, in a single machining process of a product, the product needs to be polished for multiple times, so that the coefficient β is usually set to 3-5.
Further, defining the point set of the tact of the past processing as T, and the tact, i.e. the time difference between the two production completion records, then:
T＝{Ti|Ti＝Si+1-Si}。
further, defining the process stability as σ, and the process stability is the stability of the previous tact, i.e. variance, then:
furthermore, the method also comprises the following steps of comparing the acquired volume intensity with a volume threshold value in real time, and if the volume intensity is higher than the volume threshold value, giving an alarm through short message notification. Because the acquisition module does not have a buzzer or an alarm lamp, the alarm is given by short message notification. Therefore, a noise alarm volume threshold value is set for the equipment, and when the volume is detected to be higher than the volume threshold value, an alarm short message is sent to related personnel.
As shown in fig. 3, in this embodiment, the apparatus for implementing the detection method includes a noise collector 1, an equipment-side collection box 2, a workshop-side production line large screen 103, and a server 4. The device end acquisition box 2 comprises a control module 5, a touch display module 6 and a WiFi module 7. The workshop end production line large screen 103 comprises a wireless routing module 8, an industrial personal computer 9 and a production line large screen 10.
Furthermore, the noise collector 1 is preferably a sound pickup; the equipment end collecting box 2 is a module which is additionally arranged beside an electric control cabinet of the equipment in a control cabinet mode, and the noise collector 1 is contained in the module. The control module 5 is preferably a card computer internally running an RT-Linux system, and a 16G SD card is used as a data storage and application program for storing 1 month noise data acquired by one device at a high frequency of 1HZ (the total amount of data is kept at 260W, and the data time exceeds 1 month and is automatically cleared). The touch display module 6 is preferably a 5.5-inch touch liquid crystal display screen, and can be simply configured (mainly IP address, equipment number and server connection configuration). The WiFi module 7 is preferably a wireless WiFi sending module and is used for converting the acquired signals into Modbus-TCP signals and sending the Modbus-TCP signals to the industrial personal computer 9 at the workshop end in a wireless WiFi mode.
Furthermore, the production line large screen 103 at the workshop end is a module installed in the workshop in a mode of a medium-sized electric control cabinet. The wireless routing module 8 adopts a 4G wireless industrial router, and has the functions of receiving messages sent by an acquisition module on a production line and performing service processing, wherein a 4G logistics card needs to be inserted, and flow rate fee needs to be paid monthly. The industrial personal computer 9 is used for summarizing and sorting collected data of equipment in a workshop and displaying and interacting the production line large screen 10. The industrial personal computer 9 has another function of storing collected data in the database server 4 after being sorted. In this embodiment, the production line large screen 10 is preferably a 65-inch large screen all-in-one machine, and includes a touch screen, a liquid crystal display, and a microcomputer inside. The server 4 may be an intranet server deployed in an enterprise central machine room, and for an enterprise without such hardware condition, the data may be directly stored in a public network cloud database.
Claims (2)
1. A detection method for calculating the capacity of equipment by collecting the noise of the equipment is characterized by comprising the following steps: the method comprises the following steps:
step one, collecting the on-site volume of the equipment, and storing data to obtain a volume change curve graph taking time t as an abscissa and volume intensity f (t) as an ordinate;
step two, acquiring a volume change curve when the high-noise auxiliary machine operates and defining the volume change curve as a noise curve;
thirdly, performing data analysis on the noise curve, calculating the equipment state from the equipment noise volume, calculating the equipment state change record from the equipment state, calculating the production period from the equipment state change record, calculating the previous production beat from the production period, and calculating the process stability from the previous production beat;
wherein, defining the point set of the device state change record in the noise curve as S, then:
calculating the production-standby change times of the equipment based on the count value of the number of wave crests of the noise curve to obtain the capacity of the equipment;
the wavelength of the noise curve corresponds to the production beat, a point set of the past production beat is defined as T, the production beat is the time difference recorded by the completion of two times of production, and then:
T＝{Tj|Tj＝tj+1-tj}; wherein, tj+1-tjIs the time difference between two peaks in the noise curve;
defining the process stability as sigma, then:
2. the method as claimed in claim 1, wherein the method comprises the steps of: and comparing the obtained volume intensity with a volume threshold in real time, and if the volume intensity is higher than the volume threshold, giving an alarm through short message notification.
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