CN112053464A - Remote fault diagnosis method and system for heading machine - Google Patents
Remote fault diagnosis method and system for heading machine Download PDFInfo
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Abstract
The invention discloses a remote fault diagnosis method and a remote fault diagnosis system for a heading machine, wherein the remote fault diagnosis method for the heading machine comprises the following steps: acquiring field equipment data, field support data and alarm information by using a data acquisition unit deployed in the heading machine; receiving field device data, field support data and alarm information sent by a data acquisition unit through a remote transmission device; and obtaining a diagnosis result corresponding to the alarm information according to the field equipment data and the field support data. The method considers the supporting condition of the surrounding rock on site, and obtains a diagnosis result corresponding to the alarm information by using the field equipment data and the field supporting data. Compared with the prior art, the method has the advantages that influence factors are considered more comprehensively, so that the diagnosis result is more accurate and reliable, and the diagnosis method is quicker, more convenient and more efficient. The remote fault diagnosis system of the heading machine can realize the remote fault diagnosis method of the heading machine and has the beneficial effects.
Description
Technical Field
The invention relates to the technical field of remote diagnosis, in particular to a remote fault diagnosis method for a heading machine. In addition, the invention also relates to a remote fault diagnosis system of the heading machine, which realizes the remote fault diagnosis method of the heading machine.
Background
The tunnel boring machine is a large tunnel construction equipment integrating mechanical, electrical, hydraulic, optical and gas systems, and is widely applied to tunnel engineering of China railway, hydropower, traffic, mine, municipal engineering and the like. The tunnel boring machine mainly comprises a boring machine, a pipe jacking machine, a rock tunnel boring machine and the like.
With the development of the tunneling technology, the construction landform of the tunneling machine is more and more complex, which puts higher requirements on the reliability of the control system of the tunneling machine.
In the prior art, when a control system of the tunnel boring machine has problems, technicians are usually required to go out to the site for problem troubleshooting, the time spent is long, and the timeliness for solving the problems is poor.
In order to meet the construction requirements of rapid, efficient and safe tunneling, a remote fault diagnosis technology for diagnosing and maintaining a remote control system by using a network is gradually generated, however, the current remote fault diagnosis method of the tunneling machine mainly monitors and analyzes the state parameters of the electric control system of the tunneling machine, and does not consider the surrounding rock condition and the supporting condition of a tunnel construction site, that is, the obtained information is not comprehensive, so that technical personnel cannot judge the site more comprehensively, therefore, the remote fault diagnosis cannot be effectively carried out, the result of the remote fault diagnosis is inaccurate, and the reliability is not high.
Therefore, how to provide a remote fault diagnosis method for a heading machine to enable a diagnosis result to be more accurate and reliable is a problem to be urgently solved by technical personnel in the field at present.
Disclosure of Invention
In view of this, the invention aims to provide a remote fault diagnosis method and system for a heading machine, which have more accurate and reliable diagnosis results.
In order to achieve the above purpose, the invention provides the following technical scheme:
a remote fault diagnosis method for a heading machine comprises the following steps:
acquiring field equipment data, field support data and alarm information by using a data acquisition unit deployed in the heading machine;
receiving the field device data, the field support data and the alarm information which are sent by the data acquisition unit through a remote transmission device;
and obtaining a diagnosis result corresponding to the alarm information according to the field equipment data and the field support data.
Preferably, the process of obtaining the field support data comprises:
setting a preset distance for two adjacent pause photographing of the heading machine according to the photographing visual angle range of an image collector arranged on the heading machine so that the image collector can collect in-tunnel image information of the full construction length of the rock tunnel;
setting a preset number of image acquisition points when the heading machine pauses to take pictures each time according to the range of the shooting visual angle so that the image acquisition device can acquire 360-degree image information in the cave;
controlling the heading machine to pause for a preset time every time the heading machine runs for the preset distance;
acquiring pictures shot by the image collector at each image acquisition point;
acquiring support information and surrounding rock information according to the picture;
and splicing all pictures shot by the image collector by utilizing an image splicing technology, and importing the support information and the surrounding rock information corresponding to the mileage by taking the mileage as an axis to form a three-dimensional image which is displayed visually in three dimensions, wherein the three-dimensional image is the field support data.
Preferably, before the data collector sends the field device data, the field support data and the alarm information through the remote transmission device, the method further includes:
classifying the field device data and the field support data into structured data and unstructured data according to a time axis sequence;
compressing the structured data, the unstructured data and the alarm information.
Preferably, the receiving the field device data, the field support data and the alarm information sent by the data collector through a remote transmission device includes:
and receiving the encrypted field device data, the field support data and the alarm information which are sent by the data acquisition unit through a remote transmission device.
Preferably, the process of sending the field device data, the field support data and the alarm information by the data collector through a remote transmission device includes:
when the alarm information exists, the alarm information is preferentially sent;
and sending the field equipment data, the field support data and the alarm information by adopting a breakpoint continuous transmission technology.
Preferably, before obtaining a diagnosis result corresponding to the alarm information according to the field device data and the field support data, the method further includes:
judging whether target alarm information identical to the alarm information exists in prestored historical alarm information or not;
if so, calling out a target diagnosis result corresponding to the target alarm information according to the corresponding relation between the historical alarm information and the historical diagnosis result;
and if not, the step of obtaining a diagnosis result corresponding to the alarm information according to the field equipment data and the field support data is carried out.
Preferably, after obtaining a diagnosis result corresponding to the alarm information, the method further includes:
obtaining a processing scheme corresponding to the diagnosis result according to the diagnosis result;
and sending the processing scheme to an on-site server through the remote transmission equipment.
A remote fault diagnosis system for a heading machine, comprising:
the data acquisition unit is deployed on the heading machine and used for acquiring field equipment data, field support data and alarm information;
and the remote fault diagnosis center is connected with the data acquisition unit so as to receive the field device data, the field support data and the alarm information which are sent by the data acquisition unit through a remote transmission device, and obtain a diagnosis result corresponding to the alarm information according to the field device data and the field support data.
Preferably, the data collector includes an image collecting system for collecting the field supporting data, and the image collecting system includes three image collecting modules, which are respectively:
the first image acquisition module is arranged in front of a steel arch assembling ring of the tunneling machine and used for acquiring image information of surrounding rocks;
the second image acquisition module is arranged between the rear supporting leg of the development machine and the spraying and mixing mechanism and is used for acquiring the steel arch assembly condition and the bolting condition of the jumbolter;
and the third image acquisition module is arranged behind the spraying and mixing mechanism and is used for acquiring the concrete spraying condition.
Preferably, each of the image acquisition modules comprises:
the plane of the support ring is parallel to the cross section of the surrounding rock;
the image collector is connected with the support ring in a sliding manner;
and the driving device is connected with the image collector and is used for driving the image collector to rotate along the support ring so that the image collector can be sequentially positioned at a plurality of preset image collecting points and can collect 360-degree image information in the rock cavern.
According to the remote fault diagnosis method for the heading machine, provided by the invention, when the diagnosis result corresponding to the alarm information is obtained, the on-site surrounding rock support condition is considered, and the diagnosis result corresponding to the alarm information is obtained by utilizing the on-site equipment data and the on-site support data.
Compared with the prior art that the diagnosis result is determined only according to the state parameters of the electric control system of the heading machine, obviously, the remote fault diagnosis method of the heading machine has more comprehensive considered influence factors, so that the diagnosis result is more accurate and reliable.
Meanwhile, compared with the method that technicians arrive at a construction site for analysis and calculation to obtain a diagnosis result, the remote diagnosis mode is quicker, more convenient and more efficient, and the economy is improved.
The remote fault diagnosis system of the heading machine, provided by the invention, can realize the remote fault diagnosis method of the heading machine and has the beneficial effects.
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 embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the provided drawings without creative efforts.
Fig. 1 is a flowchart of a remote fault diagnosis method for a heading machine according to an embodiment of the present invention;
fig. 2 is a schematic view of the arrangement of an image acquisition system on a heading machine in the remote fault diagnosis system for a heading machine according to the embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating the image collector shown in FIG. 2 splicing the taken pictures at each image collecting point;
FIG. 4 is a schematic diagram of a single image capture module in FIG. 2 capturing a picture at a predetermined image capture point;
fig. 5 is a block diagram of a remote fault diagnosis system of a heading machine according to an embodiment of the present invention;
fig. 6 is a flow chart of the operation of the remote fault diagnosis system of the heading machine shown in fig. 5.
The reference numerals in fig. 2 to 5 are as follows:
the system comprises a data acquisition device 1, a first image acquisition module 11, a second image acquisition module 12, a third image acquisition module 13, an image acquisition device 111, a support ring 112, an image acquisition point 113, an acquisition range 114, an image acquisition device visual angle alpha, an image acquisition angle beta, a remote fault diagnosis center 2, a technician remote client, a steel arch assembly ring 4, a jumbolter 5, a rear support leg 6, a jet mixing mechanism 7 and a surrounding rock 8.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. 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 core of the invention is to provide the remote fault diagnosis method and the remote fault diagnosis system for the heading machine, and the diagnosis result is more accurate and reliable.
Referring to fig. 1, a flowchart of a remote fault diagnosis method for a heading machine according to an embodiment of the present invention is shown.
The invention provides a remote fault diagnosis method for a heading machine, which comprises the following steps of S1 to S3:
step S1: and acquiring field equipment data, field support data and alarm information by using a data acquisition unit deployed in the heading machine.
It should be noted that the field device data in the present invention mainly includes working parameters of the heading machine, such as pressure, temperature, liquid level, flow rate, displacement, angle, rotation speed, and deviation.
It can be understood that the data collector for detecting the working parameters may be corresponding various sensors, and the specific types and models of the various sensors are not limited in the present invention, and can be selected by those skilled in the art according to actual needs.
Of course, the field device data may also include HMI setting parameters and the like.
In addition, the on-site support data mainly comprises guide mileage data, steel arch mechanism, jumbolter mechanism, jet mixing mechanism sensor data, steel arch position and specification, jumbolter position data, anchor rod length specification data, jet mixing position data, jet mixing amount data and the like.
The data collector for obtaining the field support data can be an image collector, a video and/or audio collecting device and the like.
The alarm information mainly comprises abnormal alarm information and alarm time given by a PLC of the development machine, and corresponding relations between field equipment data and field support data acquired by a data acquisition device and the alarm time respectively.
It should be noted that the invention does not limit the specific deployment mode of the data collector in the heading machine, and those skilled in the art can arrange the data collector according to actual requirements.
Step S2: and receiving field device data, field support data and alarm information sent by the data acquisition unit through the remote transmission device.
The data acquisition device comprises a data acquisition unit, a remote fault diagnosis center and a data transmission unit, wherein the data acquisition unit is used for acquiring data of the field equipment, the field support data and the alarm information, and the data acquisition unit is used for acquiring the data of the field equipment, the field support data and the alarm information.
It should be noted that the specific implementation manner of the remote transmission device is not limited in the present invention, as long as the remote transmission of the field device data, the field support data and the alarm information can be implemented.
Step S3: and obtaining a diagnosis result corresponding to the alarm information according to the field equipment data and the field support data.
That is, when the diagnostic result corresponding to the alarm information is obtained, the invention considers the situation of the field surrounding rock support, and obtains the diagnostic result corresponding to the alarm information by using the field device data and the field support data.
Compared with the prior art that the diagnosis result is determined only according to the state parameters of the electric control system of the heading machine, obviously, the remote fault diagnosis method of the heading machine has more comprehensive considered influence factors, so that the diagnosis result is more accurate and reliable.
Meanwhile, compared with the method that technicians arrive at a construction site for analysis and calculation to obtain a diagnosis result, the remote diagnosis mode is quicker, more convenient and more efficient, and the economy is improved.
In view of the specific manner of obtaining the field support data, on the basis of the above embodiment, the process of obtaining the field support data includes the following steps:
the method comprises the following steps: and setting a preset distance for two adjacent pause photographing of the heading machine according to the photographing visual angle range of the image collector arranged on the heading machine so that the image collector can collect the in-tunnel image information of the full construction length of the rock tunnel.
It can be understood that the preset distance between two adjacent stop pictures of the heading machine needs to ensure that pictures shot by the image collector when the heading machine stops at each time can be continuously spliced in the direction taking the mileage as the axis (namely the advancing direction of the heading machine), so that the image information in the cave within the full construction length range of the rock cave can be restored by the image splicing technology subsequently.
Step two: and setting a preset number of image acquisition points when the heading machine pauses to take pictures each time according to the shooting visual angle range of the image acquisition device, so that the image acquisition device can acquire 360-degree image information in the rock cavern.
Similarly, the shooting visual angle range of the image collector is limited, and one image collector can not cover 360-degree tunnel image information of the full section of the rock tunnel once for shooting, so that when the heading machine stops once and the image collector collects a section of tunnel image information, a plurality of image collecting points need to be arranged, a plurality of image collectors can be adopted to respectively take pictures at the plurality of image collecting points, one image collector can also sequentially move to the plurality of image collecting points to take pictures, so that the pictures taken by the image collector during each stop of the heading machine can be continuously spliced in the circumferential direction, and the image information in the tunnel within the full section range of 360 degrees can be subsequently restored through an image splicing technology.
It can be understood that after the preset distance between two adjacent pause photographing of the heading machine and the preset number of image acquisition points of the heading machine during each pause photographing are set, the images are regularly photographed and acquired in the heading process of the heading machine, and the following steps from three to five are carried out.
Step three: and controlling the heading machine to pause for a preset time every time the heading machine runs for a preset distance.
Step four: and acquiring pictures shot by the image acquisition device at each image acquisition point.
Step five: and acquiring support information and surrounding rock information according to pictures shot by the image acquisition device at each image acquisition point.
Step six: and splicing all pictures shot by the image collector by utilizing an image splicing technology, and importing support information and surrounding rock information corresponding to the mileage by taking the mileage as an axis to form a three-dimensional image which is displayed visually, wherein the three-dimensional image is field support data.
That is to say, in this embodiment, pictures of all full sections within the full construction length range of the cave are shot through the image collector, all the pictures shot by the image collector are seamlessly spliced by using the splicing technology, and a three-dimensional image which is three-dimensionally and visually displayed is formed by taking the mileage as an axis, so as to restore the situation of the on-site surrounding rock support, so that a technician at a remote end can visually, clearly and clearly know the situations of the on-site surrounding rock, the support and the like without going to the site.
Further, in order to obtain the on-site supporting conditions such as the surrounding rock condition before construction, the steel arch assembly condition, the bolting condition of the bolting machine, and the like, and the concrete spraying condition of the construction site, and the like, on the basis of the above embodiments, the method for acquiring the pictures shot by the image acquisition device at each image acquisition point includes:
acquiring first pictures shot by a first image collector arranged in front of a steel arch assembly ring of the heading machine at each corresponding image collecting point;
acquiring second pictures shot by a second image collector arranged between a rear supporting leg and a spraying and mixing mechanism of the heading machine at each corresponding image collecting point;
and acquiring a third picture shot by a third image acquisition device arranged behind the spray mixing mechanism at each corresponding image acquisition point.
It can be understood that after all the first pictures shot by the first image collector are seamlessly spliced, three-dimensional data of surrounding rocks before construction can be obtained; after all second pictures shot by the second image collector are seamlessly spliced, comprehensive supporting conditions such as steel arch frame splicing conditions and anchor rod drilling conditions of an anchor rod drilling machine can be obtained; and after all third pictures shot by the third image collector are seamlessly spliced, the concrete spraying condition of the construction site can be obtained.
That is to say, in the embodiment, different image collectors are arranged at different positions of the heading machine to respectively correspond to the field supporting conditions such as the surrounding rock condition before construction, the steel arch assembly condition, the bolting condition of the jumbolter and the like, and the concrete spraying condition of the construction field, so that the field supporting data is more accurate.
In addition, it can be seen that, because the field device data and the field support data have the problems of large, large and complicated data volume, etc., in order to facilitate the review or management of the field device data and the field support data, on the basis of the above embodiments, before the data collector sends the field device data, the field support data and the alarm information through the remote transmission device, the method further includes:
the field device data and the field support data are classified into structured data and unstructured data according to a time axis sequence.
That is, after the data collector collects the corresponding data, the field device data and the field support data are classified, so that the field device data and the field support data are classified and managed conveniently.
As will be appreciated by those skilled in the art, structured data refers primarily to data that can be logically represented and implemented using a two-dimensional table structure; the unstructured data mainly comprises office documents, XML, HTML, various reports, pictures, audio and video information and the like in all formats.
Further, after the field device data and the field support data are classified, the structured data, the unstructured data and the alarm information are preferably classified and stored, that is, the structured data, the unstructured data and the alarm information are respectively stored in a structured database, an unstructured database and an alarm information database, so that various construction information collected at corresponding time points under different mileage in the tunneling process can be conveniently recorded and stored.
Further, for convenience of transmission and storage, after the field device data and the field support data are classified into the structured data and the unstructured data according to the time axis sequence, the method further comprises the following steps:
and compressing the structured data, the unstructured data and the alarm information.
In addition, in view of the lack of security of the remote transmission data, the easy attack by the network, and the like, on the basis of the above embodiments, the receiving data collector receives the field device data, the field support data and the alarm information sent by the remote transmission device, and includes:
and receiving the encrypted field device data, the field support data and the alarm information which are sent by the data acquisition unit through the remote transmission equipment.
That is to say, before the data acquisition unit sends the field device data, the field support data and the alarm information through the remote transmission device, the encryption technology is adopted to encrypt the field device data, the field support data and the alarm information so as to transmit the encrypted field device data, the encrypted field support data and the encrypted alarm information, and the safety of the data is ensured.
In addition, in order to provide alarm information in time, based on the above embodiments, in consideration of poor tunnel construction environment, unstable network signals, and possibly causing data transmission interruption, a process of sending field device data, field support data, and alarm information by a data collector through a remote transmission device includes:
and when the alarm information exists, the alarm information is preferentially sent.
That is, when the field device data, the field support data and the alarm information occur, the alarm information is set to be the highest priority of data transmission, so that the alarm information can be transmitted always preferentially to ensure that the alarm information can be sent in the first time.
Further, in order to ensure timeliness and reliability of data transmission, on the basis of the above embodiment, the process of sending the field device data, the field support data and the alarm information by the data collector through the remote transmission device includes:
and transmitting field equipment data, field support data and alarm information by adopting a breakpoint continuous transmission technology.
That is, the present embodiment employs a conventional breakpoint resuming technique, so that data is retransmitted from the network disconnection point, so as to ensure the time and efficiency of data transmission.
In addition, considering that the remote end can accumulate a large amount of historical tunneling data of all tunneling machines over the years along with the accumulation of time, in order to quickly locate the diagnosis result corresponding to the alarm information, the historical alarm information and the historical diagnosis result corresponding to the historical alarm information are preferably stored, so that the diagnosis result corresponding to the alarm information is searched and quickly given by comparing the alarm information with the historical alarm information.
Specifically, on the basis of the above embodiment, before obtaining a diagnosis result corresponding to the alarm information according to the field device data and the field support data, the method further includes:
judging whether target alarm information identical to the alarm information exists in prestored historical alarm information or not;
if so, calling a target diagnosis result corresponding to the target alarm information according to the corresponding relation between the historical alarm information and the historical diagnosis result;
and if not, obtaining a diagnosis result corresponding to the alarm information according to the field equipment data and the field support data.
That is to say, after receiving the alarm information, the present embodiment preferably determines whether target alarm information identical to the alarm information exists in the pre-stored historical alarm information, and if yes, directly invokes a target diagnosis result corresponding to the target alarm information; and if the alarm information does not exist, obtaining a diagnosis result corresponding to the alarm information based on the received field equipment data and the received field support data.
Further, on the basis of the above-described embodiment, when there is no target alarm information that is the same as the alarm information in the previously stored history alarm information, after a diagnosis result corresponding to the alarm information is obtained from the field device data and the field support data, the alarm information and the diagnosis result are stored in correspondence to update the history alarm information and the correspondence relationship between the history alarm information and the history diagnosis result.
It is understood that, after obtaining the diagnosis result corresponding to the alarm information according to the field device data and the field support data, it is preferable to further include:
obtaining a processing scheme corresponding to the diagnosis result according to the diagnosis result;
and sending the processing scheme to a field server through remote transmission equipment so as to guide field technicians to correspondingly process the alarm information.
It is understood that the processing schemes corresponding to the diagnosis results may be stored together, so that when there is target alarm information identical to the alarm information in the history alarm information, a target diagnosis result corresponding to the target alarm information and a target processing scheme corresponding to the target diagnosis result are called out synchronously.
If the target alarm information identical to the alarm information does not exist in the prestored historical alarm information, after a diagnosis result corresponding to the alarm information is obtained according to field device data and field support data, a technician can manually input a processing scheme corresponding to the diagnosis result so as to send the processing scheme to a field server through remote transmission equipment; meanwhile, technicians can remotely download and upload programs by accessing the industrial personal computer of the heading machine so as to modify the control programs of the heading machine.
Referring to fig. 2 to 5, fig. 2 is a schematic view illustrating a deployment of an image acquisition system on a heading machine in a remote fault diagnosis system of the heading machine according to an embodiment of the present invention; FIG. 3 is a schematic diagram illustrating the image collector shown in FIG. 2 splicing the taken pictures at each image collecting point; FIG. 4 is a schematic diagram of a single image capture module in FIG. 2 capturing a picture at a predetermined image capture point; fig. 5 is a block diagram of a remote fault diagnosis system of a heading machine according to an embodiment of the present invention.
In addition to the remote fault diagnosis method for the heading machine, the invention also provides a remote fault diagnosis system for the heading machine, which is used for realizing the remote fault diagnosis method for the heading machine disclosed by the embodiment, wherein the remote fault diagnosis system for the heading machine comprises a data acquisition unit 1 and a remote fault diagnosis center 2, and the data acquisition unit 1 is deployed in the heading machine and is used for acquiring field equipment data, field support data and alarm information; the remote fault diagnosis center 2 is connected with the data collector 1 to receive the field device data, the field support data and the alarm information sent by the data collector 1 through the remote transmission device, and obtain a diagnosis result corresponding to the alarm information according to the field device data and the field support data.
In view of a specific implementation manner of obtaining the on-site support data, on the basis of the above embodiment, as shown in fig. 2, the data acquisition device 1 includes an image acquisition system for acquiring the on-site support data, the image acquisition system includes three image acquisition modules, which are respectively a first image acquisition module 11, a second image acquisition module 12 and a third image acquisition module 13, and the first image acquisition module 11 is arranged in front of the steel arch assembling ring 4 of the heading machine and is used for acquiring image information of the surrounding rock 8; the second image acquisition module 12 is arranged between the rear support leg 6 and the spraying and mixing mechanism 7 of the heading machine and is used for acquiring the steel arch assembly condition and the bolting condition of the jumbolter 5; the third image acquisition module 13 is arranged behind the spraying and mixing mechanism 7 and is used for acquiring the concrete spraying condition.
As can be seen, in the embodiment, the first image acquisition module 11, the second image acquisition module 12 and the third image acquisition module 13 are used for acquiring image information of different positions in the construction process of the heading machine, so as to comprehensively restore the three-dimensional data of the surrounding rock 8 before construction, the steel arch assembly condition, the bolting condition of the bolting machine 5, and the like, and the concrete spraying condition of the construction site.
In order to enable each image acquisition module to obtain corresponding full-section information, on the basis of the above-mentioned embodiments, as shown in fig. 3 and fig. 4, each image acquisition module includes a supporting ring 112, an image collector 111, and a driving device, where the plane of the supporting ring 112 is parallel to the cross section of the surrounding rock 8, the image collector 111 is slidably connected with the supporting ring 112, and the driving device is connected with the image collector 111 and is used for driving the image collector 111 to rotate along the supporting ring 112, so that the image collector 111 can be sequentially positioned at a plurality of preset image acquisition points 113, and the image collector 111 is enabled to acquire 360 ° image information in the rock cavern.
It should be noted that the present embodiment does not limit the specific determination method of the image capturing point 113. For example, as shown in fig. 3, according to the image capturing angle α of the image capturing device 111, the shooting range of the image capturing device 111 can be determined, and further, according to the shooting range, the image capturing angle β can be determined, so that the specific number of the image capturing points 113 can be obtained by dividing 360 ° by the image capturing angle β. As shown in fig. 3, the image capturing point 113 is located on the bisector of the image capturing angle β.
Further, as shown in fig. 4, an acquisition range 114 of a single image acquirer 111 at a single image acquisition point 113 is shown.
In addition, as shown in fig. 5, in order to obtain the field device data and facilitate processing of the field device data and the field support data, the data acquisition unit 1 further includes an industrial personal computer, a switch, a PLC of the heading machine, a field device sensor, a video sound system, an HMI, a field server, a big data processing platform, and the like, wherein the field device sensor is connected to the PLC of the heading machine, the PLC, the HMI, the image acquisition system, the video sound system, and the like are connected to the industrial personal computer through the switch, the industrial personal computer is connected to the field server through a bus, and the big data processing platform may be connected to the field server, or the field server may be provided with the big data processing platform.
It will be appreciated that the field device sensors include sensors for sensing pressure, temperature, level, flow, displacement, angle, speed, yaw and other operating parameters of the machine.
The big data processing platform preferably comprises a classification module, a data processing module, a data storage module and a data compression module.
Specifically, the data processing module is used for processing image information acquired by the image acquisition system, the image acquisition system is used for shooting pictures of all full sections in the full construction length range of the cave, the data processing module preferably utilizes a splicing technology to seamlessly splice all the pictures shot by the image acquisition system, and the mileage is taken as an axis to form a three-dimensional image which is displayed in a three-dimensional visual mode so as to restore the supporting condition of the surrounding rock 8 on site.
The data classification module is used for classifying the field device data and the field support data into structured data and unstructured data according to a time axis sequence.
The data storage module comprises a structured database, an unstructured database and an alarm information database, so that the structured data, the unstructured data and the alarm information are respectively stored in the databases corresponding to the structured database, the unstructured database and the alarm information.
The data compression module is used for compressing the structured data, the unstructured data and the alarm information.
In addition, the on-site server is used to connect with the remote failure diagnosis center 2 through the internet.
The remote failure diagnosis center 2 includes a VPN server, a database server, and a technology center. The VPN server, the database server and the technical center are connected through a local area network in a company.
Preferably, the presence server is connected to the VPN server via the internet.
The database server is preferably provided with a second big data processing platform, and the second big data processing platform comprises a historical data module, a real-time data module, a second data processing module, a data searching module and the like.
Specifically, the historical data module is used for storing mass historical tunneling data of all tunneling machines in the past year, and the mass historical tunneling data comprises historical alarm information and a corresponding relation between the historical alarm information and a historical diagnosis result.
The real-time data module is used for storing tunneling information, such as field device data, field support data and alarm information, sent by each field construction tunneling machine in real time.
And the second data processing module is used for comparing the alarm information with the historical alarm information so as to judge whether target alarm information which is the same as the alarm information exists in the prestored historical alarm information, and calling a target diagnosis result corresponding to the target alarm information according to the corresponding relation between the historical alarm information and the historical diagnosis result when the target alarm information which is the same as the alarm information is found. And when the target alarm information identical to the alarm information is not searched, obtaining a diagnosis result corresponding to the alarm information according to the field equipment data and the field support data.
Further, the second data processing module is further configured to, when there is no target alarm information that is the same as the alarm information in the pre-stored historical alarm information, after obtaining a diagnosis result corresponding to the alarm information according to the field device data and the field support data, correspondingly store the alarm information and the diagnosis result, so as to update the historical alarm information and a corresponding relationship between the historical alarm information and the historical diagnosis result.
The data search module is used for a technician to search specific data information required by the technician for access.
In addition, the technology center contains multiple computers.
When the alarm information is sent to the VPN server from the field server, a technician accesses the VPN server through a computer of the technical center to check the alarm information.
When the pre-stored historical alarm information has the target alarm information which is the same as the alarm information, the technical center computer receives the target alarm information transmitted from the database server and the corresponding target diagnosis result, at the moment, a technician can select an intelligent remote fault processing mode, and directly transmits the target diagnosis result to the field server through the VPN server, so that the field technician can process the fault.
When the pre-stored historical alarm information does not have target alarm information which is the same as the alarm information, a technician can select a manual remote fault processing mode, obtain a diagnosis result corresponding to the alarm information according to field device data and field support data, transmit the diagnosis result to a VPN server in an input mode, and send the diagnosis result to the field server through the VPN server so as to guide construction.
Of course, an automatic remote fault processing mode can be set according to a conventional calculation mode, so that a diagnosis result corresponding to the alarm information can be automatically obtained according to the field device data and the field support data.
In the process, if the control program needs to be modified, a technician directly accesses an industrial personal computer of the heading machine through the VPN server to realize remote uploading and downloading of the program.
Furthermore, in order to ensure that a technician can timely process the fault condition of the construction site even if the technician is not at a company, the timeliness of fault processing is further improved.
The remote fault diagnosis system of the heading machine further comprises a technician remote client 3, and the technician remote client 3 is connected with the remote fault diagnosis center 2 through the Internet or networks such as GSM/GPRS/3G/4G and the like.
Specifically, the technician remote client 3 includes an encryption laptop, computer or other encryption device, etc. to enable the technician to access the corporate VPN server via the internet or a network such as GSM/GPRS/3G/4G.
As shown in fig. 6, the work flow of the remote fault diagnosis system of the heading machine shown in fig. 5 is shown.
Specifically, the industrial personal computer acquires field device data, field support data and alarm information in real time, wherein the field device data, the field support data and the alarm information comprise information acquired by a field device sensor, an image acquisition system, an HMI (human machine interface), a video sound system, alarm information sent by a PLC (programmable logic controller) and the like.
And the industrial personal computer transmits the acquired field equipment data and field support data to the field server through the bus.
And the field server splices the picture data acquired by the image acquisition system through the big data processing platform, and classifies, compresses, stores and the like the field equipment data and the field support data.
And the field server transmits the alarm information, the processed field equipment data and the field support data to a VPN server of the remote fault diagnosis center 2 in real time through the VPN encrypted internet.
The VPN server stores the received data information into the database server and transmits the alarm information to the technical center.
The technical center receives alarm information transmitted by the VPN server and a target diagnosis result sent by the database server and gives a diagnosis result corresponding to the alarm information; or the technical center receives the alarm information transmitted by the VPN server and the field device data and the field support data transmitted by the database server, and obtains a diagnosis result corresponding to the alarm information according to the field device data and the field support data.
A technician not at the company accesses the company VPN server through the technician remote client 3 to process the failure information.
It is further noted that, in the present specification, relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.
The remote fault diagnosis method and system for the heading machine provided by the invention are described in detail above. The principles and embodiments of the present invention are explained herein using specific examples, which are presented only to assist in understanding the method and its core concepts. It should be noted that, for those skilled in the art, it is possible to make various improvements and modifications to the present invention without departing from the principle of the present invention, and those improvements and modifications also fall within the scope of the claims of the present invention.
Claims (10)
1. A remote fault diagnosis method for a heading machine is characterized by comprising the following steps:
acquiring field equipment data, field support data and alarm information by using a data acquisition unit deployed in the heading machine;
receiving the field device data, the field support data and the alarm information which are sent by the data acquisition unit through a remote transmission device;
and obtaining a diagnosis result corresponding to the alarm information according to the field equipment data and the field support data.
2. The remote fault diagnosis method of the heading machine according to claim 1, wherein the process of obtaining the field support data comprises:
setting a preset distance for two adjacent pause photographing of the heading machine according to the photographing visual angle range of an image collector arranged on the heading machine so that the image collector can collect in-tunnel image information of the full construction length of the rock tunnel;
setting a preset number of image acquisition points when the heading machine pauses to take pictures each time according to the range of the shooting visual angle so that the image acquisition device can acquire 360-degree image information in the cave;
controlling the heading machine to pause for a preset time every time the heading machine runs for the preset distance;
acquiring pictures shot by the image collector at each image acquisition point;
acquiring support information and surrounding rock information according to the picture;
and splicing all pictures shot by the image collector by utilizing an image splicing technology, and importing the support information and the surrounding rock information corresponding to the mileage by taking the mileage as an axis to form a three-dimensional image which is displayed visually in three dimensions, wherein the three-dimensional image is the field support data.
3. The remote fault diagnosis method for the heading machine according to claim 1, wherein before the data acquisition unit sends the field device data, the field support data and the alarm information through the remote transmission device, the method further comprises:
classifying the field device data and the field support data into structured data and unstructured data according to a time axis sequence;
compressing the structured data, the unstructured data and the alarm information.
4. The remote fault diagnosis method for the heading machine according to claim 1, wherein the receiving of the field device data, the field support data and the alarm information sent by the data collector through a remote transmission device comprises:
and receiving the encrypted field device data, the field support data and the alarm information which are sent by the data acquisition unit through a remote transmission device.
5. The remote fault diagnosis method for the heading machine according to claim 1, wherein the process of sending the field device data, the field support data and the alarm information by the data collector through a remote transmission device comprises:
when the alarm information exists, the alarm information is preferentially sent;
and sending the field equipment data, the field support data and the alarm information by adopting a breakpoint continuous transmission technology.
6. The remote fault diagnosis method of the heading machine according to any one of claims 1 to 5, further comprising, before obtaining a diagnosis result corresponding to the alarm information based on the field device data and the field support data:
judging whether target alarm information identical to the alarm information exists in prestored historical alarm information or not;
if so, calling out a target diagnosis result corresponding to the target alarm information according to the corresponding relation between the historical alarm information and the historical diagnosis result;
and if not, the step of obtaining a diagnosis result corresponding to the alarm information according to the field equipment data and the field support data is carried out.
7. The remote fault diagnosis method of the heading machine according to claim 6, further comprising, after obtaining a diagnosis result corresponding to the alarm information:
obtaining a processing scheme corresponding to the diagnosis result according to the diagnosis result;
and sending the processing scheme to an on-site server through the remote transmission equipment.
8. A remote fault diagnosis system for a heading machine is characterized by comprising:
the data acquisition unit (1) is deployed on the heading machine and used for acquiring field equipment data, field support data and alarm information;
and the remote fault diagnosis center (2) is connected with the data acquisition unit (1) so as to receive the field device data, the field support data and the alarm information which are sent by the data acquisition unit (1) through a remote transmission device, and obtain a diagnosis result corresponding to the alarm information according to the field device data and the field support data.
9. The remote fault diagnosis system of the heading machine according to claim 8, wherein the data collector (1) comprises an image collection system for collecting the field support data, and the image collection system comprises three image collection modules, which are respectively:
the first image acquisition module (11) is arranged in front of the steel arch assembly ring (4) of the heading machine and is used for acquiring image information of surrounding rocks (8);
the second image acquisition module (12) is arranged between the rear supporting leg (6) and the spraying and mixing mechanism (7) of the heading machine and is used for acquiring the steel arch assembly condition and the bolting condition of the bolting machine (5);
and the third image acquisition module (13) is arranged behind the spraying and mixing mechanism (7) and is used for acquiring the concrete spraying condition.
10. The remote fault diagnosis system of a heading machine according to claim 9, wherein each of the image acquisition modules comprises:
a support ring (112) lying in a plane parallel to the cross section of the surrounding rock (8);
an image collector (111) which is connected with the support ring (112) in a sliding way;
and the driving device is connected with the image collector (111) and is used for driving the image collector (111) to rotate along the supporting ring (112), so that the image collector (111) can be sequentially positioned at a plurality of preset image collecting points (113), and the image collector (111) collects 360-degree image information in the rock cavern.
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