CN111970155A - Intelligent early warning system for fault state of crane equipment - Google Patents
Intelligent early warning system for fault state of crane equipment Download PDFInfo
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- H04L41/06—Management of faults, events, alarms or notifications
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- H04L41/06—Management of faults, events, alarms or notifications
- H04L41/069—Management of faults, events, alarms or notifications using logs of notifications; Post-processing of notifications
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Abstract
The invention discloses an intelligent early warning system for the fault state of crane equipment, which comprises: the data acquisition module is used for acquiring the operation data of a plurality of crane devices; the server stores the operation data and sets model data and alarm conditions; the data analysis processing module is used for analyzing and processing the operation data according to the model data and uploading the analysis result to the server for storage; the state judgment module is used for judging and analyzing the analysis result periodically according to the alarm condition and sending out alarm information when the state is abnormal; and the query module is used for data query. The invention realizes early warning of the abnormal state of the crane equipment, is convenient for maintenance personnel to carry out scheduled maintenance, reduces the damage of other parts caused by the abnormal operation of the crane equipment, reduces the cost of spare parts, avoids abnormal shutdown caused by faults in the operation process and has high reliability.
Description
Technical Field
The invention relates to the technical field of equipment fault early warning, in particular to an intelligent early warning system for a fault state of crane equipment.
Background
With the development of the current logistics industry, the requirements on the wharf are continuously improved, both in terms of operation efficiency and reliability; however, as an important part of the wharf operation, many control and protection theories of wharf operation crane equipment still continue to be the norm and method for decades ago, that is, the necessary detection logic is established through an editable controller of a control system of the crane equipment, and when the component state of the crane equipment does not meet a certain logic, an alarm or fault prompt is set off, so that the operation of the crane equipment is stopped. The method has the fatal defects that when the equipment stops running, a fault occurs, and a maintainer can only carry out remediation after the problem occurs, and often the equipment is used as a ring of a production system to carry out production operation with very high test piece requirements, the shutdown of the equipment can bring about great economic loss to a wharf; meanwhile, in order to ensure that production can be recovered in the shortest time when equipment fails or is unexpected during operation, technical departments of the wharfs need to prepare a large number of spare parts, and the need is met from time to time, so that huge operation cost is brought to the wharfs; therefore, it is necessary to provide an intelligent early warning system for the fault state of the crane equipment, so as to early warn the abnormal state of the crane in advance when the crane equipment has not failed, so that maintenance personnel can perform planned maintenance in advance, thereby reducing the damage of other parts caused by the abnormal operation of the equipment, reducing the cost of spare parts, avoiding the occurrence of faults in the operation process, and improving the reliability of the equipment in the operation process.
The present invention has been developed based on this.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides an intelligent early warning system for the fault state of crane equipment.
The technical scheme of the invention is as follows:
the utility model provides a loop wheel machine equipment fault state intelligence early warning system, includes:
the data acquisition module comprises a plurality of acquisition terminals, and each acquisition terminal is used for acquiring the operation data of one crane device in real time and transmitting the acquired operation data to the server for storage;
the server is in communication connection with the data acquisition module and is used for receiving and storing all the operation data acquired by the acquisition terminal, and meanwhile, the server is also used for setting model data of a plurality of crane equipment and corresponding alarm conditions;
the data analysis processing module is in communication connection with the server and used for analyzing and processing the operation data stored by the server according to the model data of the crane equipment and transmitting the analysis result to the server for storage;
the state judgment module is in communication connection with the server and used for periodically making state judgment on an analysis result stored by the server according to the alarm condition of crane equipment, transmitting the judgment result to the server for storage, and generating alarm information to a user according to a preset alarm path when the state is abnormal;
and the query module is in communication connection with the server and is used for querying required data according to query conditions of the user and forming an analysis report in a required format.
Furthermore, each acquisition terminal comprises a sensor group matched with the number of the parts of the crane equipment, each part of each crane equipment is provided with one sensor group, and each sensor group is used for acquiring the operation data of the corresponding part in real time and transmitting the acquired data to a server for storage through a data transmission device.
Furthermore, each sensor group comprises a plurality of temperature sensors for acquiring the operating temperature of the component, distance sensors for acquiring the braking distance of the component, torque sensors for acquiring the torque borne by the component, pressure sensors for acquiring the pressure borne by the component and vibration sensors for acquiring the vibration displacement of the component.
Further, the server comprises a raw database and a central database; the original database is in communication connection with all the sensor groups through a data transmission device and is used for receiving and storing the operation data collected by the sensor groups, and the original database gives a timestamp to each received operation data; the data analysis processing module is respectively in communication connection with the original database and the central database, the central database is also in communication connection with the state judgment module, and the central database is used for receiving and storing data transmitted by the data analysis processing module and the state judgment module and setting model data of a plurality of crane devices and alarm conditions corresponding to the model data;
the model data of each crane device comprises model data of each component of the crane device, and correspondingly, the alarm condition comprises an alarm condition of each component of the crane device.
Further, the data analysis processing module periodically transfers the operation data of the specified time period in the original database to a central database, analyzes and processes the operation data of the specified time period in the original database according to the model data of each part of the crane equipment, and transmits the analysis result to the central database for storage.
Further, the analysis processing comprises the comparative analysis between the operation data of each part of each crane equipment in the specified time period in the original database and the model data of each part of the corresponding crane equipment and/or the data comparison between the part operation data of one crane equipment in the operation data in the specified time period in the original database and the operation data of the same part of the other crane equipment of the same type, correspondingly, the analysis result comprises a comparison analysis result between the operation data of each part of each crane equipment in the specified time period in the original database and the model data of each part of the corresponding crane equipment and/or a data comparison result between the part operation data of one crane equipment in the operation data in the specified time period in the original database and the operation data of the same part of the other crane equipment of the same type.
Further, the state judgment module periodically judges the state of the analysis result stored in the central database according to the alarm condition of each part of the crane equipment, transmits the judgment result to the central processing unit for storage, and generates alarm information to a user according to a preset alarm path when the state is abnormal.
Further, the method for judging the state of the crane equipment by the state judgment module is to judge the state of the crane equipment by judging the continuous variation trend of the operation data of the component corresponding to the analysis result of each component of the crane equipment in a specified time period; when the continuous variation trend of the operation data continuously changes towards a preset alarm threshold value, and the continuous variation trend extends to the development change time of the alarm threshold value and continues the early warning time or the variation frequency of the continuous variation trend reaches the early warning frequency, judging that the state of a component corresponding to the operation data is abnormal, and at the moment, generating alarm information according to a preset alarm path by the state judgment module and transmitting the alarm information to a user through a mobile terminal in communication connection with the state judgment module to play an early warning role;
when the operation data of a certain part of the crane equipment tends to be stable within a specified time and the continuous change trend of the operation data of the part continuously increases, the state of the part corresponding to the operation data is judged to be abnormal, and the state judgment module 4 generates alarm information according to a preset alarm path and transmits the alarm information to a user through a mobile terminal in communication connection with the alarm path;
further, when the continuous variation trend of a certain part of the crane equipment is in normal variation, but the average value of the running data of the part is always larger than the average value of the running data corresponding to the same part of different crane equipment with the same working environment and type as the crane equipment, and the average value of the running data of the part exceeds the average value of the running data of the same part of different crane equipment with the same type as the crane equipment and reaches a preset proportion, the state of the part is judged to be abnormal, and the state judgment module 4 generates alarm information according to a preset alarm path and transmits the alarm information to a user through a mobile terminal in communication connection with the alarm.
Further, the query module comprises a main control computer, the main control computer is in communication connection with the central database, and a user queries corresponding data in the central database through a query instruction issued by the main control computer, and forms an analysis report to be transmitted to the main control computer.
By adopting the scheme, the invention has the following beneficial effects:
according to the invention, the abnormal state of the crane equipment is early warned in advance by real-time acquisition and analysis of the operation data of the crane equipment, so that maintenance personnel can conveniently perform scheduled maintenance, the damage of other parts caused by the abnormal operation of the crane equipment is avoided, the cost of spare parts is reduced, the abnormal shutdown of the crane equipment due to fault occurrence in the operation process is effectively avoided, and the reliability is improved.
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 structures shown in the drawings without creative efforts.
FIG. 1 is a schematic diagram of the system of the present invention.
The implementation, functional features and advantages of the objects of the present invention will be further explained with reference to the accompanying drawings.
Detailed Description
The invention is described in detail below with reference to the figures and the specific embodiments.
Referring to fig. 1, the present invention further provides an intelligent early warning system for a fault state of a crane device, including:
the data acquisition module 1 comprises a plurality of acquisition terminals, and each acquisition terminal is used for acquiring the operation data of one crane device in real time and transmitting the acquired operation data to the server 2 for storage;
the server 2 is in communication connection with the data acquisition module 1 and is used for receiving and storing all the operation data acquired by the acquisition terminal, and meanwhile, the server 2 is also used for setting model data of a plurality of crane devices and alarm conditions corresponding to the model data;
the data analysis processing module 3 is in communication connection with the server 2, and is used for analyzing and processing the operation data stored in the server 2 according to the model data of the crane equipment and transmitting the analysis result to the server 2 for storage;
the state judgment module 4 is in communication connection with the server 2, and is used for periodically making state judgment on an analysis result stored in the server 2 according to an alarm condition of crane equipment, transmitting the judgment result to the server 2 for storage, and generating alarm information to a user according to a preset alarm path when the state is abnormal;
and the query module 5 is in communication connection with the server 2 and is used for querying required data according to query conditions of a user and forming an analysis report in a required format.
In this embodiment, each of the acquisition terminals includes a sensor group whose number is matched with that of the components of the crane equipment, each component of each of the crane equipment is provided with one sensor group, and the sensor group is used for acquiring the operation data of the corresponding component in real time and transmitting the acquired data to the server 2 for storage through the data transmission device;
furthermore, each sensor group comprises a plurality of temperature sensors for acquiring the operating temperature of the component, distance sensors for acquiring the braking distance of the component, torque sensors for acquiring the torque borne by the component, pressure sensors for acquiring the pressure borne by the component and vibration sensors for acquiring the vibration displacement of the component.
In the present embodiment, the server 2 includes a raw database 21 and a central database 22; the original database 21 is in communication connection with all the sensor groups through a data transmission device, and is used for receiving and storing the operation data acquired by the sensor groups, and the original database 21 gives a timestamp to each received operation data; the data analysis processing module 3 is respectively in communication connection with the original database 21 and the central database 22, the central database 22 is also in communication connection with the state judgment module 4, and the central database 22 is used for receiving and storing data transmitted by the data analysis processing module 3 and the state judgment module 4, and setting model data of a plurality of crane devices and alarm conditions corresponding to the model data;
the model data of each crane device comprises model data of each component of the crane device, and correspondingly, the alarm condition comprises an alarm condition of each component of the crane device.
In this embodiment, the data analysis processing module 3 periodically migrates the operation data in the original database 21 within a specified time period to the central database 22, analyzes the operation data in the original database 21 within the specified time period according to the model data of each component of the crane equipment, and transmits the analysis result to the central database 22 for storage;
wherein the analysis process comprises the comparison analysis of the operation data of each part of each crane equipment in the specified time period in the original database 21 and the model data of each part of the corresponding crane equipment and/or the data comparison of the operation data of one crane equipment in the operation data in the specified time period in the original database 21 and the operation data of the same part of the other crane equipment of the same type, correspondingly, the analysis result includes a comparison analysis result between the operation data of each component of each crane equipment in the specified time period in the original database 21 and the model data of each component of the corresponding crane equipment, and/or a data comparison result between the component operation data of one crane equipment in the operation data in the specified time period in the original database 21 and the same component operation data of the other crane equipment of the same type.
In this embodiment, the state judgment module 4 periodically makes state judgment on the analysis result stored in the central database 22 according to the alarm condition of each component of the crane equipment, transmits the judgment result to the central processing unit for storage, and generates alarm information to the user according to a preset alarm path when the state is abnormal;
the state judgment module 4 is used for judging the state of the crane equipment by judging the continuous change trend of the operation data of the components corresponding to the analysis results of the components of the crane equipment in a specified time period; when the continuous variation trend of the operation data continuously changes towards a preset alarm threshold, and the continuous variation trend extends to the development change time of the alarm threshold for the duration of the early warning time or the variation frequency of the continuous variation trend reaches the early warning frequency, judging that the state of a component corresponding to the operation data is abnormal, and at the moment, generating alarm information according to a preset alarm path by the state judgment module 4 and transmitting the alarm information to a user through a mobile terminal in communication connection with the alarm path, so as to play a role of early warning;
when the operation data of a certain part of the crane equipment tends to be stable within a specified time and the continuous change trend of the operation data of the part continuously increases, the state of the part corresponding to the operation data is judged to be abnormal, and the state judgment module 4 generates alarm information according to a preset alarm path and transmits the alarm information to a user through a mobile terminal in communication connection with the alarm path;
further, when the continuous variation trend of a certain part of the crane equipment is in normal variation, but the average value of the running data of the part is always larger than the average value of the running data corresponding to the same part of different crane equipment with the same working environment and type as the crane equipment, and the average value of the running data of the part exceeds the average value of the running data of the same part of different crane equipment with the same type as the crane equipment and reaches a preset proportion, the state of the part is judged to be abnormal, and the state judgment module 4 generates alarm information according to a preset alarm path and transmits the alarm information to a user through a mobile terminal in communication connection with the alarm.
In this embodiment, the query module 5 includes a main control computer, the main control computer is in communication connection with the central database 22, and a user queries corresponding data in the central database 22 through a query instruction issued by the main control computer, and forms an analysis report to transmit to the main control computer.
Compared with the prior art, the invention has the following beneficial effects:
according to the invention, the abnormal state of the crane equipment is early warned in advance by real-time acquisition and analysis of the operation data of the crane equipment, so that maintenance personnel can conveniently perform scheduled maintenance, the damage of other parts caused by the abnormal operation of the crane equipment is avoided, the cost of spare parts is reduced, the abnormal shutdown of the crane equipment due to fault occurrence in the operation process is effectively avoided, and the reliability is improved.
The present invention is not limited to the above preferred embodiments, and any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (9)
1. The utility model provides a loop wheel machine equipment fault state intelligence early warning system which characterized in that includes:
the data acquisition module comprises a plurality of acquisition terminals, and each acquisition terminal is used for acquiring the operation data of one crane device in real time and transmitting the acquired operation data to the server for storage;
the server is in communication connection with the data acquisition module and is used for receiving and storing all the operation data acquired by the acquisition terminal, and meanwhile, the server is also used for setting model data of a plurality of crane equipment and corresponding alarm conditions;
the data analysis processing module is in communication connection with the server and used for analyzing and processing the operation data stored by the server according to the model data of the crane equipment and transmitting the analysis result to the server for storage;
the state judgment module is in communication connection with the server and used for periodically making state judgment on an analysis result stored by the server according to the alarm condition of crane equipment, transmitting the judgment result to the server for storage, and generating alarm information to a user according to a preset alarm path when the state is abnormal;
and the query module is in communication connection with the server and is used for querying required data according to query conditions of the user and forming an analysis report in a required format.
2. The intelligent early warning system for the fault state of the crane equipment as claimed in claim 1, wherein each acquisition terminal comprises a sensor group matched with the number of the components of the crane equipment, each component of each crane equipment is provided with one sensor group respectively, and the sensor groups are used for acquiring the operation data of the corresponding component in real time and transmitting the acquired data to a server for storage through a data transmission device.
3. The intelligent early warning system for the fault state of the crane equipment as claimed in claim 2, wherein each sensor group comprises a plurality of temperature sensors for acquiring the operating temperature of the component, distance sensors for acquiring the braking distance of the component, torque sensors for acquiring the torque borne by the component, pressure sensors for acquiring the pressure borne by the component and vibration sensors for acquiring the vibration displacement of the component.
4. The intelligent early warning system of the fault state of the crane equipment as claimed in claim 2, wherein the server comprises a raw database and a central database; the original database is in communication connection with all the sensor groups through a data transmission device and is used for receiving and storing the operation data collected by the sensor groups, and the original database gives a timestamp to each received operation data; the data analysis processing module is respectively in communication connection with the original database and the central database, the central database is also in communication connection with the state judgment module, and the central database is used for receiving and storing data transmitted by the data analysis processing module and the state judgment module and setting model data of a plurality of crane devices and alarm conditions corresponding to the model data;
the model data of each crane device comprises model data of each component of the crane device, and correspondingly, the alarm condition comprises an alarm condition of each component of the crane device.
5. The intelligent early warning system for the fault state of the crane equipment as claimed in claim 4, wherein the data analysis processing module periodically migrates the operation data in the specified time period in the original database to a central database, analyzes and processes the operation data in the specified time period in the original database according to the model data of each component of the crane equipment, and transmits the analysis result to the central database for storage.
6. The intelligent early warning system for the fault state of the crane equipment as claimed in claim 5, wherein the analysis process includes a comparison analysis between the operation data of each component of each crane equipment within a specified period of time in the original database and the model data of each component of the corresponding crane equipment and/or a data comparison between the component operation data of one crane equipment in the operation data within the specified period of time in the original database and the same component operation data of the other crane equipment of the same type, and correspondingly, the analysis result includes a comparison analysis result between the operation data of each component of each crane equipment within the specified period of time in the original database and the model data of each component of the corresponding crane equipment and/or a component operation data of one crane equipment in the operation data within the specified period of time in the original database and the same component operation data of the other crane equipment of the same type Data comparison results between component operational data.
7. The intelligent early warning system for the fault state of the crane equipment as claimed in claim 6, wherein the state judgment module periodically makes state judgment on the analysis result stored in the central database according to the alarm condition of each component of the crane equipment, transmits the judgment result to the central processing unit for storage, and generates alarm information to a user according to a preset alarm path when the state is abnormal.
8. The intelligent early warning system for the fault state of the crane equipment as claimed in claim 7, wherein the state judgment module is used for judging the state of the crane equipment by judging the continuous variation trend of the operation data of the component corresponding to the analysis result of each component of the crane equipment in a specified time period; when the continuous variation trend of the operation data continuously changes towards a preset alarm threshold value, and the continuous variation trend extends to the development change time of the alarm threshold value and continues the early warning time or the variation frequency of the continuous variation trend reaches the early warning frequency, judging that the state of a component corresponding to the operation data is abnormal, and at the moment, generating alarm information according to a preset alarm path by the state judgment module and transmitting the alarm information to a user through a mobile terminal in communication connection with the state judgment module to play an early warning role;
when the running data of a certain part of the crane equipment tends to be stable within a specified time and the continuous change trend of the running data of the part continuously increases, the state of the part corresponding to the running data is judged to be abnormal, and the state judgment module generates alarm information according to a preset alarm path and transmits the alarm information to a user through a mobile terminal in communication connection with the alarm path;
further, when the continuous change trend of a certain part of the crane equipment is in normal change, but the average value of the running data of the part is always larger than the average value of the running data corresponding to the same part of different crane equipment with the same working environment and type as the crane equipment, and the average value of the running data of the part exceeds the average value of the running data of the same part of different crane equipment with the same type as the crane equipment and reaches a preset proportion, the state of the part is judged to be abnormal, and the state judgment module generates alarm information according to a preset alarm path and transmits the alarm information to a user through a mobile terminal in communication connection with the alarm.
9. The intelligent early warning system for the fault state of the crane equipment as claimed in claim 4, wherein the query module comprises a main control computer, the main control computer is in communication connection with the central database, and a user queries corresponding data in the central database through a query instruction issued by the main control computer, and forms an analysis report to be transmitted to the main control computer.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114415581A (en) * | 2021-12-28 | 2022-04-29 | 广东德尔智慧工厂科技有限公司 | Mechanical equipment operation and maintenance method and system |
| CN114385719A (en) * | 2022-01-25 | 2022-04-22 | 广东潜力会科技发展有限公司 | Digitalized equipment fault predicting system based on multi-data acquisition and analysis |
| CN114593845A (en) * | 2022-03-04 | 2022-06-07 | 蚌埠高灵传感系统工程有限公司 | Load sensor safety monitoring system based on internet |
| CN114593845B (en) * | 2022-03-04 | 2024-05-28 | 蚌埠高灵传感系统工程有限公司 | Load sensor safety monitoring system based on internet |
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