CN112051756A - Pneumatic actuator fault diagnosis recorder - Google Patents
Pneumatic actuator fault diagnosis recorder Download PDFInfo
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- CN112051756A CN112051756A CN201910484925.0A CN201910484925A CN112051756A CN 112051756 A CN112051756 A CN 112051756A CN 201910484925 A CN201910484925 A CN 201910484925A CN 112051756 A CN112051756 A CN 112051756A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0428—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/21—Pc I-O input output
- G05B2219/21137—Analog to digital conversion, ADC, DAC
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Abstract
The embodiment of the invention discloses a fault diagnosis recorder for a pneumatic actuating mechanism. The pneumatic actuator fault diagnosis recorder can detect the instruction sent by a detection superior system to the intelligent positioner to calculate the theoretical data of each parameter of the pneumatic actuator, acquire the actual state data of each parameter of the pneumatic actuator, and compare the theoretical data with the actual state data during fault diagnosis, so as to diagnose whether the pneumatic actuator is in a fault state and judge a fault point to give an alarm.
Description
Technical Field
The invention relates to the technical field of automation, in particular to a fault diagnosis recorder for a pneumatic actuating mechanism.
Background
The pneumatic actuating mechanism and the automatic control system thereof are a system which takes an air compressor as a power source and takes compressed air as a working medium to carry out energy transmission and signal transmission and realize the automatic control of the industrial process. The pneumatic actuator and the automatic control system thereof are one of the important means for realizing automation, and have a series of advantages of high working efficiency, low cost, no pollution and the like, so the pneumatic actuator and the automatic control system thereof are more and more widely applied to the industrial fields of electric power, papermaking, machinery, chemical industry, metallurgy, food, medicine and the like.
Due to the defects of low medium compressibility and sealing-caused friction force and natural frequency, small damping ratio, poor rigidity, poor control timeliness, serious nonlinearity and the like in the pneumatic actuator and an automatic control system thereof, great difficulty is caused on the control accuracy, stability, safety, maintainability and the like of the pneumatic actuator. The intelligent positioner which is most widely used in the current process industry and is used for the pneumatic actuating mechanism with the straight stroke and the angular stroke has the function of positioning control, and can realize the control of any position of the pneumatic actuating mechanism. With the improvement of the intelligent level and the continuous development of big data analysis technology, the parameter recording and fault diagnosis functions of the pneumatic actuating mechanism in the operation process are required.
However, because the diagnostic function of the current intelligent positioner is single and uncontrollable, and the service life and the number of times of use of hardware are generally used as the basis for fault judgment, the accuracy for judging the position and the cause of a fault point is limited, and the maintenance efficiency of the pneumatic actuator is reduced. Therefore, it is necessary to develop a fault diagnosis recorder for a pneumatic actuator to solve the above problems.
Disclosure of Invention
The invention aims to provide a fault diagnosis recorder for a pneumatic actuating mechanism, which can effectively help maintenance personnel to judge the position and the reason of a fault point and improve the maintenance efficiency.
The invention provides a fault diagnosis recorder for a pneumatic actuating mechanism, which comprises: the touch control display device comprises a data acquisition device, a data processing device and a touch control display device, wherein the data acquisition device is in communication connection with the data processing device, and the data processing device is in communication connection with the touch control display device;
the data acquisition device is used for acquiring actual state data of each parameter of the pneumatic actuating mechanism;
the data processing device is used for detecting an instruction sent by a superior system to the intelligent positioner, calculating theoretical data of each parameter of the pneumatic actuating mechanism according to the instruction and the database model, acquiring actual state data of each parameter of the pneumatic actuating mechanism, comparing whether the theoretical data is consistent with the actual state data, if the theoretical data is inconsistent with the actual state data, calculating an error value between the theoretical data and the actual state data, judging whether the error value is within an error allowable range, if the error value is not within the error allowable range, judging that the pneumatic actuating mechanism is in a fault state, analyzing to obtain fault analysis data, and sending the fault analysis data to the touch display device;
and the touch display device is used for displaying the fault analysis data and sending out a fault alarm.
Optionally, the data acquisition device includes a sensor disposed at each measurement point of the pneumatic actuator, and the sensor at least includes: displacement sensor, pressure sensor and temperature sensor.
Optionally, the actual state data at least includes: the actual displacement value of the cylinder, the pressure value of each measuring point of the cylinder, the actual pressure value or the tension value between the cylinder and the load, and the temperature value of each measuring point of the cylinder.
Optionally, the instruction detected by the data processing apparatus is the last instruction actually executed by the intelligent locator, and is used as a precondition instruction for fault diagnosis.
Optionally, the data processing apparatus detects an instruction sent by the superior system to the intelligent locator in the following manner:
and the data processing device acquires the voltage value on the detection resistor, and calculates the instruction sent to the intelligent positioner by the superior system by combining the ohm law I with U/R.
Optionally, the actual state data acquired by the data processing device is the actual data of the pneumatic actuating mechanism in a stable state after the intelligent positioner executes the precondition instruction.
Optionally, the data processing device is an STM32 embedded system, the touch display device is a capacitive 7-inch serial port screen, and the data processing device communicates with the touch display device through an RS232 serial port bus.
Optionally, the fault alarm includes a screen flashing alarm, an indicator light alarm and a buzzer alarm.
Optionally, the fault analysis data at least includes: fault type, fault cause, and fault point location.
Optionally, the data processing device is further configured to identify whether the fault type is a preset serious fault type after determining that the pneumatic actuator is in a fault state and analyzing the fault analysis data, and output a relay signal if the fault type is the preset serious fault type.
The pneumatic actuating mechanism fault diagnosis recorder can detect the instruction sent by a superior system to the intelligent positioner to calculate the theoretical data of each parameter of the pneumatic actuating mechanism, acquire the actual state data of each parameter of the pneumatic actuating mechanism, and compare the theoretical data with the actual state data during fault diagnosis, so as to diagnose whether the pneumatic actuating mechanism is in a fault state and judge a fault point to give an alarm.
Drawings
In order to more clearly illustrate the technical solution of the present invention, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious to those skilled in the art that other drawings can be obtained based on these drawings without creative efforts.
Fig. 1 is a schematic diagram of a fault diagnosis recorder for a pneumatic actuator according to an embodiment of the present invention.
Fig. 2 is a flowchart of diagnosing a fault in a data processing apparatus according to an embodiment of the present invention.
Fig. 3 is a flowchart of a data processing apparatus for diagnosing a fault according to an alternative embodiment of the present invention.
FIG. 4 is a schematic diagram of an STM32 embedded system.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below with reference to the specific embodiments of the present invention and the accompanying drawings. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. The technical solutions provided by the embodiments of the present invention are described in detail below with reference to the accompanying drawings.
Referring to fig. 1, fig. 1 is a schematic diagram of a fault diagnosis recorder for a pneumatic actuator according to an embodiment of the present invention. The pneumatic actuator fault diagnosis recorder is used for diagnosing and recording faults of the pneumatic actuator 103, and executing corresponding actions on the pneumatic actuator 103 according to instructions of the superior system 101 under the control of the intelligent positioner 102.
Wherein, this pneumatic actuator fault diagnosis record appearance includes: a data acquisition device 104, a data processing device 105 and a touch display device 106. The data acquisition device 104 is in communication connection with the data processing device 105, and the data processing device 105 is in communication connection with the touch display device 106.
The data acquisition device 104 may be any of various types of sensors disposed at corresponding measurement points on the pneumatic actuator 103 for acquiring actual status data of various parameters of the pneumatic actuator 103. The data processing device 105 can diagnose the fault according to the actual state data of each parameter of the pneumatic actuator 103 and the database model provided by the experiment table 107, and send the fault result to the touch display device 106 for displaying and alarming.
Referring to fig. 2, a flowchart of a data processing apparatus for diagnosing a fault according to an embodiment of the present invention specifically includes the following steps:
step S201, the data processing device detects an instruction sent by the superior system to the intelligent locator.
In this embodiment, the instruction detected by the data processing apparatus is the last instruction actually executed by the intelligent locator, and is used as a precondition instruction for fault diagnosis. Specifically, the data processing device may detect the instruction sent by the superior system to the intelligent locator in the following manner:
and the data processing device acquires the voltage value on the detection resistor, and calculates the instruction sent to the intelligent positioner by the superior system by combining the ohm law I with U/R.
And S202, calculating theoretical data of each parameter of the pneumatic actuating mechanism by the data processing device according to the instruction and the database model.
In step S203, the data processing device obtains actual state data of each parameter of the pneumatic actuator.
In this embodiment, the data acquisition device 104 may specifically include a sensor disposed at each measurement point of the pneumatic actuator, where the sensor at least includes: displacement sensor, pressure sensor and temperature sensor. The actual state data at least comprises: the actual displacement value of the cylinder, the pressure value of each measuring point of the cylinder, the actual pressure value or the tension value between the cylinder and the load, and the temperature value of each measuring point of the cylinder. And the actual state data acquired by the data processing device is the actual data of the pneumatic actuating mechanism in a stable state after the intelligent positioner executes the precondition instruction.
Step S204, the data processing device compares whether the theoretical data is consistent with the actual state data.
In step S205, if the theoretical data is not consistent with the actual state data, the data processing device calculates an error value between the theoretical data and the actual state data.
In step S206, the data processing apparatus determines whether the error value is within the error allowable range.
And step S207, if the error value is not in the error allowable range, the data processing device judges that the pneumatic actuator is in a fault state and analyzes to obtain fault analysis data.
For example, if the change range and the change frequency of the position of the cylinder piston in the pneumatic actuator 103 exceed the set range within a certain time range, it is determined that the piston has a vibration fault, and then the specific fault point and the cause are determined according to specific parameters and logic. For another example, if the cylinder position is always at the zero point or the end point position after the pneumatic actuator 103 executes the non-zero and non-end point commands, it is determined that there is an air leakage phenomenon at a certain point of the pneumatic actuator 103, and then the specific fault point and the cause are determined according to the specific parameter and logic. For another example, if the position of the cylinder piston of the pneumatic actuator 103 is always constant regardless of the change of the command, it is judged as an air supply failure or the like.
In step S208, the data processing device sends the failure analysis data to the touch display device.
After receiving the failure analysis data, the touch display device 106 displays the failure analysis data, and sends a failure alarm to remind relevant personnel of coming maintenance. The fault analysis data includes at least: fault type, fault reason and fault point position, and the fault alarm may include screen flashing alarm, indicator light alarm, buzzer alarm, etc.
In an alternative embodiment, as shown in fig. 3, the data processing device 105 is further configured to execute step S301 after determining that the pneumatic actuator is in a failure state and analyzing the failure analysis data, and identifying whether the failure type is a preset serious failure type. The type of catastrophic failure may be predetermined. If the fault type is a preset serious fault type, step S302 is executed to output a relay signal and control the relay to be turned off, so as to protect the system.
According to the technical scheme, the fault diagnosis recorder for the pneumatic actuating mechanism can detect the instruction sent by a superior system to the intelligent positioner to calculate the theoretical data of each parameter of the pneumatic actuating mechanism, acquire the actual state data of each parameter of the pneumatic actuating mechanism, and compare the theoretical data with the actual state data during fault diagnosis, so that whether the pneumatic actuating mechanism is in a fault state or not is diagnosed, and a fault point can be judged to give an alarm.
It should be noted that the fault diagnosis recorder for the pneumatic actuator of the present invention determines that there is no fault in each sensor of the system, and determines that the corresponding error between the sensor and the converting circuit is not enough to affect the determination result, i.e. the error between the sensor and the converting circuit is within the allowable range.
The fault diagnosis recorder for the pneumatic actuating mechanism can be suitable for fault diagnosis of the following pneumatic actuating mechanisms: the air cylinder system comprises a single-acting air cylinder without an amplifier and an air lock valve, a single-acting air cylinder with the amplifier and the air lock valve, a double-acting air cylinder without the amplifier and the air lock valve, a double-acting air cylinder with the amplifier and the air lock valve, a single-acting film type regulating valve without the amplifier and the air lock valve, and a single-acting film type regulating valve with the amplifier and the air lock valve.
The fault diagnosable by the fault diagnosis recorder of the pneumatic actuating mechanism comprises the following steps: increased valve resistance (including a plug), air leakage of a positioner, air leakage of a pipeline connecting part, air leakage in a cylinder, air leakage of an amplifier, reversing failure of a reversing valve, untight closing of the valve and the like.
The fault diagnosis recorder for the pneumatic actuating mechanism not only analyzes, detects fault hidden danger, judges fault positions, counts fault related data and gives an alarm through data collected by the sensor, but also has the functions of counting and analyzing long-term working intervals of the valve, valve action frequency, accumulated use times and use time and displaying in a historical curve and numerical value mode. In addition, the fault diagnosis recorder of the pneumatic actuating mechanism can also be provided with a locator fault protection function. When the intelligent positioner 102 fails, the state of the pneumatic actuating mechanism 103 can be maintained, the state before the failure is maintained, the pneumatic actuating mechanism 103 is prevented from being influenced by the failure of the intelligent positioner 102 until the failure is eliminated, and the system can be manually or automatically recovered after the normal state of the system is recovered.
As shown in fig. 4, in this embodiment, the data processing device 105 may specifically be an STM32 embedded system, the touch display device 106 may be a capacitive 7-inch serial port screen, and the data processing device 105 and the touch display device 106 communicate through an RS232 serial port bus. The STM32 embedded system adopts modular design technology, and mainly comprises an embedded core board, a communication module, a power supply module, an AD acquisition module, a digital input and output module, an SD card recording module and the like.
The main functions of the STM32 embedded system include: and acquiring real-time data of planned data acquisition points such as air source pressure and the like, and sending the data to the touch display device 106 according to a communication protocol. Through analyzing the data collected by the sensor, whether the valve resistance is increased (including the jam), the gas leakage of the positioner, the gas leakage in the cylinder and other faults are judged according to the fault diagnosis logic. If a fault is detected, the fault information to be displayed is sent to the touch display device 106. In addition, the STM32 embedded system can also be used for counting fault information, system state and other related data and storing the data into the SD card.
The various modules of the STM32 embedded system will be described in detail below.
The embedded core board is a core processor, and adopts an embedded ARM system core board which takes STM32F103ZE as a main control chip and is matched with a power supply circuit, a crystal oscillator circuit, a reset circuit and a program burning circuit. The core processor is provided with a power supply voltage stabilizing chip, plays an important role in filtering and voltage stabilizing, and ensures the reliability of the power supply. The core processor leads out a commonly used necessary I/O pin, so that the core processor is conveniently connected with the peripheral equipment; an SWD simulation debugging downloading interface is led out, and the debugging simulation downloading interface can be used for downloading, so that the method is convenient and simple. The program can be developed by Keil programming software, and the compiled program can be downloaded by an SWD mode or an ISP mode.
The serial port inside the core processor has a communication function, and can be used as a communication interface to realize serial communication with the touch screen. The input and output of the touch screen are RS-232 level, and the input and output of the serial port of the core processor are TTL level. Since the TTL level and the RS-232 level are not compatible with each other, level conversion is necessary when the TTL level and the RS-232 level communicate with each other. RS232/TTL level conversion can be performed through a MAX232 chip.
The touch screen adopted by the system needs 5-40V voltage for power supply, the MAX232 interface chip needs 5V voltage for power supply, and the STM32 embedded processor needs 3.3V voltage for power supply. By comprehensive consideration, a 24V power supply is determined to be adopted for supplying power to the system, the MAX232 interface chip is supplied with power through the DC 24V-to-DC 5V voltage reduction and voltage stabilization circuit, and then the STM32 embedded core processor is supplied with power through the DC 5V-to-DC3.3V voltage reduction and voltage stabilization circuit.
The current signal output by the sensor needs to be converted into a voltage signal through a precise measuring resistor, and then analog-to-digital conversion is carried out through an A/D converter built in the core processor. The digital input is realized by reading the on-off state of the contacts of the external device, in order to prevent the high voltage of the external device from damaging the core processor system and to avoid interference signals from entering the core processor system. Optoelectronic isolation devices are used in digital quantity input circuits to isolate the core processor from external devices. In order to store related data in the running process of a system to achieve a power-off data protection function, an SD card storage module is added.
The touch display device 106 may have various configuration controls such as buttons, text, pull-down menus, progress bars, sliders, meters, animations, two-dimensional codes, data records, curves, circular progress bars, and the like. The STM32 embedded system can realize corresponding functions only by sending corresponding serial port instructions. The development and debugging of the serial port touch screen are realized through visual TFT software, and the built-in virtual serial port screen can be used for simulating and debugging the display interface of the fault diagnosis recorder of the pneumatic actuator. Has good man-machine interface. The display displays data in real time and can perform various operations such as data display and menu operation through the keyboard.
The experiment table 107 can be designed into a visual operation interface by the configuration king, is connected with a database to read fault data of the cylinder, and finally outputs an analog signal through an analog output module. In order to verify the effectiveness of system design and theoretical research, tests are required to simulate the process of occurrence and the state of occurrence of various faults. The experiment table converts the change of each parameter from digital quantity to analog quantity by simulating the condition of the cylinder when the cylinder runs with or without fault, thereby generating a 4-20mA current signal for a fault diagnosis recorder of a pneumatic actuating mechanism to collect so as to verify the effectiveness of system design and theoretical research.
The whole experiment table is provided with a visual operation interface through a configuration king, each parameter of the air cylinder can be modified in real time on the interface, the fault parameters of the air cylinder prestored in the database can also be read, data are transmitted to the analog quantity output module through an RS485 protocol, and the pneumatic actuating mechanism fault diagnosis recorder judges whether a fault occurs or not by collecting the operation parameters of the air cylinder.
The upper computer display platform mainly reads the cylinder fault measured value stored in the database through the configuration module, displays the dynamic effect of the cylinder on the configuration interface, and transmits the data of air pressure, piston position and the like to the analog quantity output module through a 485 protocol. The configuration interface of the simulation test system of the experiment table is designed by adopting visual programming software, the fault data of the database can be directly selected and read on the interface, the parameters required by fault diagnosis are displayed and sent to the analog quantity output module, and the position of the piston can be dynamically demonstrated on the interface. The DAM module is a brand-new generation of module type data acquisition unit based on an embedded system, adopts a standard DIN35 guide rail installation mode, and is simple in field installation and flexible in use; can be applied to various fields. The module is configured with an isolation RS485 interface, can be independently communicated with a PC or a PLC, and can also be used in a networking mode with a plurality of 485 modules. The DAM-DA08 analog quantity output module adopted by the system can independently output 8 paths of analog quantity signals; the module adopts a high-performance 12-bit DA chip, and the output precision can reach +/-0.2%. It is suitable for various industrial control fields. In addition, the DAM-DA adopts a photoelectric isolation technology, so that the reliability and safety of the system can be effectively ensured.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A pneumatic actuator fault diagnosis recorder is characterized by comprising: the touch control display device comprises a data acquisition device, a data processing device and a touch control display device, wherein the data acquisition device is in communication connection with the data processing device, and the data processing device is in communication connection with the touch control display device;
the data acquisition device is used for acquiring actual state data of each parameter of the pneumatic actuating mechanism;
the data processing device is used for detecting an instruction sent by a superior system to the intelligent positioner, calculating theoretical data of each parameter of the pneumatic actuating mechanism according to the instruction and the database model, acquiring actual state data of each parameter of the pneumatic actuating mechanism, comparing whether the theoretical data is consistent with the actual state data, if the theoretical data is inconsistent with the actual state data, calculating an error value between the theoretical data and the actual state data, judging whether the error value is within an error allowable range, if the error value is not within the error allowable range, judging that the pneumatic actuating mechanism is in a fault state, analyzing to obtain fault analysis data, and sending the fault analysis data to the touch display device;
and the touch display device is used for displaying the fault analysis data and sending out a fault alarm.
2. The pneumatic actuator fault diagnosis recorder of claim 1, wherein the data acquisition device comprises sensors disposed at each measurement point of the pneumatic actuator, the sensors comprising at least: displacement sensor, pressure sensor and temperature sensor.
3. The pneumatic actuator fault diagnostic recorder of claim 2, wherein the actual status data includes at least: the actual displacement value of the cylinder, the pressure value of each measuring point of the cylinder, the actual pressure value or the tension value between the cylinder and the load, and the temperature value of each measuring point of the cylinder.
4. The pneumatic actuator fault diagnosis recorder according to claim 1, wherein the instruction detected by the data processing device is the last instruction actually executed by the intelligent positioner and is a precondition instruction for fault diagnosis.
5. The pneumatic actuator fault diagnosis recorder according to claim 1, characterized in that the data processing device detects the commands sent by the superior system to the intelligent positioner by means of:
and the data processing device acquires the voltage value on the detection resistor, and calculates the instruction sent to the intelligent positioner by the superior system by combining the ohm law I with U/R.
6. The fault diagnosis recorder for pneumatic actuators according to claim 5, wherein the actual status data acquired by the data processing device is the actual data of the pneumatic actuator in a stable state after the intelligent positioner executes the precondition command.
7. The fault diagnosis recorder for the pneumatic actuator according to claim 1, wherein the data processing device is an STM32 embedded system, the touch display device is a capacitive 7-inch serial port screen, and the data processing device and the touch display device communicate through an RS232 serial port bus.
8. The pneumatic actuator fault diagnostic recorder of claim 1, wherein the fault alarms include a screen flashing alarm, an indicator light alarm, and a buzzer alarm.
9. The pneumatic actuator fault diagnostic recorder of claim 1, wherein the fault analysis data includes at least: fault type, fault cause, and fault point location.
10. The pneumatic actuator fault diagnosis recorder of claim 9, wherein the data processing device is further configured to identify whether the fault type is a preset serious fault type after determining that the pneumatic actuator is in a fault state and analyzing the fault analysis data, and output a relay signal if the fault type is the preset serious fault type.
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| CN114897196A (en) * | 2022-05-11 | 2022-08-12 | 山东大卫国际建筑设计有限公司 | Operation management method, equipment and medium for office building water supply network |
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