CN112504709A - High-efficient concentrated quick-witted operation monitoring system - Google Patents
High-efficient concentrated quick-witted operation monitoring system Download PDFInfo
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Abstract
The invention discloses an operation monitoring system of a high-efficiency thickener, which relates to the field of metallurgical manufacturing and solves the technical problems that the operation fault of a high-efficiency compressor cannot be accurately determined and the fault cannot be efficiently and accurately eliminated by workers; the operation monitoring system is arranged, the operation state of the high-efficiency compressor is judged according to the torque of the high-efficiency compressor and the thickness of the deposition zone, and the fault in the operation state is early warned, so that the fault of the high-efficiency compressor can be accurately judged, and the operation state of the high-efficiency compressor can be monitored in real time; the conventional monitoring module is arranged, and the conventional detection is carried out on the high-efficiency compressor body, so that the normal and high-efficiency operation of the high-efficiency compressor is ensured; the invention is provided with the administrator module which dispatches workers to remove the fault according to the early warning signal of the equipment, subdivides the workers and ensures that the fault can be accurately processed.
Description
Technical Field
The invention belongs to the field of metallurgical manufacturing, relates to an intelligent monitoring technology of a high-efficiency thickener, and particularly relates to an operation monitoring system of the high-efficiency thickener.
Background
The high-efficiency thickener is suitable for dewatering concentrate and tailings in a concentrating mill, is widely applied to the industries of metallurgy, chemical industry, coal, non-metal ore dressing, environmental protection and the like, and has important significance for improving the backwater utilization rate and the underflow conveying concentration and protecting the environment. The high-efficiency thickener is not a pure sedimentation device in fact, but a novel dehydration device combined with the filtering characteristic of a mud layer.
The invention patent with the publication number of CN101703846A provides an automatic control method and a system of a high-efficiency concentrator target lifting device based on pressure signals; when the target lifting device is lifted, the steps of running the high-efficiency thickener, lifting the accumulated times, lifting the target lifting device, stopping a driving device of the mud scraper and the like are included; when the target lifting device descends, the method comprises the steps of running the high-efficiency thickener, judging the load of the mud scraper, descending the target lifting device and the like. The system comprises a plurality of operation stations, a PLC (programmable logic controller), an RI/O substation of an AOD (automatic optical inspection) system, an RI/O substation of an EAF/VOD (Ethernet over fiber/video on demand) system, an RI/O substation of a water treatment system and an RI/O substation of a dust removal system; the whole operation station is respectively connected with the PLC through the industrial Ethernet; each substation is connected with a PLC controller through a bus, and the RI/O substation of the water treatment system collects signals of a pressure sensor.
Compared with the prior art, the target lifting device of the high-efficiency thickener can be better and automatically controlled, and the running effect is good; however, the actual operation process of the high-efficiency compressor is complex, and the above scheme only analyzes data in a single working process of the high-efficiency compressor, and does not consider the influence of the previous working process, so that the analysis on the lifting and the descending of the target lifting device is not accurate, and the working efficiency of the high-efficiency compressor is reduced; therefore, the above solution still needs further improvement.
Disclosure of Invention
In order to solve the problems existing in the scheme, the invention provides an efficient thickener operation monitoring system.
The purpose of the invention can be realized by the following technical scheme: an operation monitoring system of a high-efficiency concentrator comprises a high-efficiency compressor body and a monitoring system; the high-efficiency compressor body is in communication connection with a monitoring system;
the high-efficiency compressor body comprises a concentration tank, a rake frame lifting device and a feeding device; the monitoring system comprises a processor, a historical data analysis module, an administrator module, a data storage module, an operation monitoring module and a fault detection module; the processor is respectively in communication connection with the historical data analysis module, the administrator module, the data storage module, the operation monitoring module and the conventional monitoring module; the administrator module is in communication connection with the data storage module;
the conventional monitoring module is used for monitoring conventional parameters and a shutdown process of the high-efficiency compressor;
the operation monitoring module is used for early warning and removing faults in the operation process of the high-efficiency compressor;
the intelligent terminal comprises a manager module, a staff and an intelligent terminal, wherein the manager module is used for receiving an equipment early warning signal to perform early warning and dispatching the staff to perform troubleshooting, the manager module is linearly connected with the intelligent terminal of the staff, and the intelligent terminal comprises an intelligent mobile phone, a tablet personal computer and a notebook computer.
Preferably, the step of receiving the device early warning signal by the administrator module to perform early warning and dispatching a worker includes:
the administrator module analyzes the received equipment early warning signal sent by the processor; the administrator module comprises an alarm lamp and a display screen; the equipment early warning signal comprises an operation early warning signal, an equipment maintenance signal and a maintenance early warning signal; the operation early warning signals comprise a feeding abnormal signal, an insufficient flocculation signal, an excessive flocculation signal and an underflow pump abnormal signal; the equipment maintenance signals comprise an oil level abnormal signal, an oil path leakage signal, a lubricating oil shortage signal and an oil filter blockage signal;
when the equipment early warning signal is an operation early warning signal, controlling an alarm lamp to flicker orange for early warning, and simultaneously displaying the content of the operation early warning signal by a display screen; when the equipment early warning signal is an equipment maintenance signal, controlling an alarm lamp to flash yellow to give an alarm, and simultaneously displaying the content of the equipment maintenance signal by a display screen; when the equipment early warning signal is a maintenance early warning signal, controlling an alarm lamp to flash red for alarming, and simultaneously displaying the maintenance early warning signal on a display screen;
when the flashing time of the alarm lamp reaches T3 seconds, dispatching a worker through the administrator module; wherein T3 is a preset time coefficient; when the flashing time of the alarm lamp does not reach T3 seconds, sending the flashing record of the alarm lamp to a data storage module for storage; the alarm lamp flashing record comprises the flashing color of the alarm lamp and the flashing duration of the alarm lamp.
Preferably, the specific steps of the administrator module dispatching the worker include:
acquiring a duty list through a data storage module; the name, the mobile phone number, the work age and the dispatching times of the staff of the duty table, wherein the staff comprises operation staff and equipment staff;
acquiring the work age and dispatching times of workers, and respectively marking the work age and the dispatching times as GL and PC;
acquiring a worker evaluation coefficient GPX through a formula GPX of gamma 1 × GL + gamma 2 × PC + gamma 3; wherein gamma 1, gamma 2 and gamma 3 are preset proportionality coefficients, and gamma 1, gamma 2 and gamma 3 are real numbers greater than 0;
performing descending arrangement on the worker evaluation coefficients GPX, and respectively acquiring an operation worker sequencing list and an equipment worker sequencing list;
separating the front N1 bits of the operation staff sequencing list to generate a first operation staff list, and generating a second operation staff list by the rest part of the operation staff sequencing list; separating the front N1 bits of the equipment staff sequencing list and generating a second equipment staff list, wherein the rest part of the equipment staff sequencing list generates the second equipment staff list;
when the administrator module receives an operation early warning signal, dispatching a first worker group to check the operation process of the high-efficiency compressor, wherein the first worker group respectively selects one worker from a first operation worker table and a second operation worker table; when an administrator receives an equipment maintenance signal, dispatching a second staff group to check the high-efficiency compressor body, wherein the second staff group respectively selects one staff from the first equipment staff table and the second equipment staff table; when the administrator receives the maintenance early warning signal, sending a third staff group to maintain the high-efficiency compressor body and the operation process of the high-efficiency compressor body, wherein the third staff group respectively selects one staff from the first operation staff table and the first equipment staff table;
and sending the dispatching records of the first staff group, the second staff group and the third staff group to a data storage module for storage.
Preferably, the operation monitoring system is used for monitoring the operation process of the high-efficiency compressor and early warning faults in the operation process, and comprises:
acquiring the moment of the high-efficiency compressor in real time, and marking the moment as LJ; when the moment LJ meets 0< LJ is less than or equal to K1, the moment of the high-efficiency compressor is judged to be low moment; when the torque LJ meets K2< LJ, the torque of the high-efficiency compressor is judged to be high torque; wherein K1 and K2 are preset torque thresholds, and K1< K2;
acquiring the height of a deposition zone in the high-efficiency compressor in real time, and marking the height of the deposition zone as CDG; when the height CDG of the deposition zone satisfies 0< CDG ≦ K3, determining that the deposition zone is a low deposition zone; when the deposition zone height CDG satisfies K4< CDG, then determining that the deposition zone is a high deposition zone; wherein K3 and K4 are preset deposition zone height thresholds, and K3< K4;
when the moment LJ and the height CDG of the deposition zone meet the conditions that 0< LJ is not more than K1 and 0< CDG is not more than K2 at the same time, judging that the feeding of the efficient compressor is abnormal, and sending a feeding abnormal signal to the administrator module through the processor;
when the moment LJ and the height CDG of the sedimentary belt meet 0< LJ ≤ K1 and K3< CDG at the same time, determining that the efficient compressor is under flocculated, and sending a signal of the under flocculated to the administrator module through the processor;
when the moment LJ and the height CDG of the sedimentary belt simultaneously meet K2< LJ and 0< CDG < K3, judging that the efficient compressor is over-flocculated, and sending an over-flocculated signal to an administrator module through the processor;
when the moment LJ and the height CDG of the deposition zone meet K2< LJ and K4< CDG at the same time, judging that the underflow pump of the efficient compressor is abnormal, and sending an abnormal underflow pump signal to an administrator module through a processor;
and sending the torque and the height of the deposition zone to a data storage module for storage through a processor.
Preferably, the monitoring process of the conventional monitoring module comprises:
acquiring the oil level of the speed reducer by an oil level sensor every T1 time, acquiring the ratio of the oil level of the speed reducer to the height of an oil tank of the speed reducer, recording the ratio as the oil level scale of the speed reducer, and marking the oil level scale of the speed reducer as JYK; wherein T1 is a preset time threshold;
acquiring the oil level of the hydraulic machine by an oil level sensor at intervals of T1, acquiring the ratio of the oil level of the hydraulic machine to the height of an oil tank of the hydraulic machine, recording the ratio as oil level scales of the hydraulic machine, and marking the oil level scales of the hydraulic machine as YYK;
acquiring an oil evaluation coefficient YPX through a formula YPX of alpha 1 XJYK X YYK; wherein alpha 1 is a preset proportionality coefficient, and alpha 1 belongs to [0.95,1.05 ];
when the oil evaluation coefficient YPX meets the condition that YPX is not less than 0 and not more than L1, judging that the oil level of the efficient compressor is abnormal, and sending an oil level abnormal signal to an administrator module through the processor; when the oil evaluation coefficient YPX meets L1< YPX, the oil level of the high-efficiency compressor is judged to be normal, and an oil level normal signal is sent to the administrator module through the processor; wherein L1 is a preset oil evaluation coefficient threshold;
monitoring leakage of an oil way in the high-efficiency thickener in real time, and marking a leakage monitoring result as YX; the leakage monitoring result YX takes values of 0 and 1, when YX is 1, the leakage of the oil path of the high-efficiency concentrator is shown, an oil path leakage signal is sent to the administrator module through the processor, and when YX is 0, the leakage of the oil path of the high-efficiency concentrator is not shown;
acquiring a pressure value between the rake and the slideway at intervals of T2, and marking the pressure value as TY; wherein t2 is a preset time threshold, and t1< t 2; when the pressure value TY satisfies TY > L2, the slide way is judged to be lack of lubricating oil, and a lubricating oil shortage signal is sent to the administrator module; wherein L2 is a preset pressure value threshold;
acquiring the pressure difference of two sides of the hydraulic oil filter at intervals of T2, and marking the oil filter pressure difference as YYC; when the oil filter pressure difference YYC is greater than L3, judging that the hydraulic oil filter is blocked, and sending an oil filter blocking signal to the administrator module through the processor; wherein L3 is a preset oil filtration pressure difference threshold value;
by the formula
Obtaining a maintenance evaluation coefficient JPX; wherein alpha 2 and alpha 3 are preset proportionality coefficients, and both alpha 2 and alpha 3 are real numbers larger than 0;
when the maintenance evaluation coefficient JPX meets the condition that 0 is not less than JPX < L4, the efficient compressor is judged to need maintenance, and a maintenance early warning signal is sent to the administrator module through the processor; wherein L4 is a preset maintenance evaluation coefficient threshold;
and sending the oil evaluation coefficient, the leakage monitoring result, the pressure value and the oil filter pressure difference to a data storage module for storage.
Compared with the prior art, the invention has the beneficial effects that:
1. the invention is provided with an operation monitoring system, which is used for monitoring the operation process of the high-efficiency compressor and early warning faults in the operation process; acquiring the moment LJ of the high-efficiency compressor in real time; acquiring the height CDG of a deposition zone in the high-efficiency compressor in real time; monitoring the operation fault of the high-efficiency compressor by combining the moment LJ and the height CDG of the deposition zone; the operation monitoring system judges the operation state of the high-efficiency compressor according to the torque height and the thickness of the deposition zone of the high-efficiency compressor and gives an early warning to faults in the operation state, so that the operation monitoring system is beneficial to accurately judging the faults of the high-efficiency compressor and monitoring the operation state of the high-efficiency compressor in real time;
2. the invention is provided with a conventional monitoring module, which is used for monitoring the conventional parameters and the shutdown process of the high-efficiency compressor; acquiring the ratio of the oil level of the speed reducer to the height of the oil tank of the speed reducer at intervals of T1, and recording the ratio as speed reducer oil level scales JYK; acquiring the ratio of the oil level of the hydraulic machine to the height of an oil tank of the hydraulic machine at intervals of T1, recording the ratio as oil level scales of the hydraulic machine, and marking the oil level scales of the hydraulic machine as YYK; acquiring an oil evaluation coefficient YPX; when the oil evaluation coefficient YPX meets the condition that YPX is not less than 0 and not more than L1, judging that the oil level of the efficient compressor is abnormal, and sending an oil level abnormal signal to an administrator module through the processor; when the oil evaluation coefficient YPX meets L1< YPX, the oil level of the high-efficiency compressor is judged to be normal, and an oil level normal signal is sent to the administrator module through the processor; monitoring leakage of an oil way in the high-efficiency thickener in real time, and marking a leakage monitoring result as YX; acquiring a pressure value between the rake and the slideway at intervals of T2, and marking the pressure value as TY; wherein T2 is a preset time threshold, and T1< T2; when the pressure value TY satisfies TY > L2, the slide way is judged to be lack of lubricating oil, and a lubricating oil shortage signal is sent to the administrator module; acquiring the pressure difference of two sides of the hydraulic oil filter at intervals of T2, and marking the oil filter pressure difference as YYC; when the oil filter pressure difference YYC is greater than L3, judging that the hydraulic oil filter is blocked, and sending an oil filter blocking signal to the administrator module through the processor; obtaining a maintenance evaluation coefficient JPX; when the maintenance evaluation coefficient JPX meets the condition that 0 is not less than JPX < L4, the efficient compressor is judged to need maintenance, and a maintenance early warning signal is sent to the administrator module through the processor; the conventional monitoring module performs conventional inspection on the high-efficiency compressor body, and is beneficial to ensuring the normal and high-efficiency operation of the high-efficiency compressor;
3. the invention is provided with a manager module which receives an early warning signal of equipment to carry out early warning and send a worker; the administrator module analyzes the received equipment early warning signal sent by the processor; the administrator module comprises an alarm lamp and a display screen; when the equipment early warning signal is an operation early warning signal, controlling an alarm lamp to flicker orange for early warning, and simultaneously displaying the content of the operation early warning signal by a display screen; when the equipment early warning signal is an equipment maintenance signal, controlling an alarm lamp to flash yellow to give an alarm, and simultaneously displaying the content of the equipment maintenance signal by a display screen; when the equipment early warning signal is a maintenance early warning signal, controlling an alarm lamp to flash red for alarming, and simultaneously displaying the maintenance early warning signal on a display screen; when the flashing time of the alarm lamp reaches T3 seconds, dispatching a worker through the administrator module; wherein T3 is a preset time coefficient; when the flashing time of the alarm lamp does not reach T3 seconds, sending the flashing record of the alarm lamp to a data storage module for storage; the administrator module dispatches workers to remove faults according to the equipment early warning signals, subdivides the workers, and ensures that the faults can be accurately processed.
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 drawings without creative efforts.
Fig. 1 is a schematic diagram of the principle of the present invention.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood 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.
Referring to fig. 1, a system for monitoring the operation of a high-efficiency thickener comprises a high-efficiency compressor body and a monitoring system; the high-efficiency compressor body is in communication connection with the monitoring system;
the high-efficiency compressor body comprises a concentration tank, a rake frame lifting device and a feeding device; the monitoring system comprises a processor, an administrator module, a data storage module, an operation monitoring module and a fault detection module; the processor is respectively in communication connection with the administrator module, the data storage module, the operation monitoring module and the conventional monitoring module; the administrator module is in communication connection with the data storage module;
the conventional monitoring module is used for monitoring conventional parameters and a shutdown process of the high-efficiency compressor;
the operation monitoring module is used for early warning and removing faults in the operation process of the high-efficiency compressor;
the administrator module is used for receiving the equipment early warning signal to perform early warning and dispatching a worker to perform troubleshooting, the administrator module is linearly connected with an intelligent terminal of the worker, and the intelligent terminal comprises an intelligent mobile phone, a tablet personal computer and a notebook computer.
Further, the steps of receiving the device early warning signal by the administrator module to perform early warning and dispatching the staff by the administrator module comprise:
the administrator module analyzes the received equipment early warning signal sent by the processor; the administrator module comprises an alarm lamp and a display screen; the equipment early warning signal comprises an operation early warning signal, an equipment maintenance signal and a maintenance early warning signal; the operation early warning signals comprise a feeding abnormal signal, an insufficient flocculation signal, an excessive flocculation signal and an underflow pump abnormal signal; the equipment maintenance signals comprise an oil level abnormal signal, an oil path leakage signal, a lubricating oil shortage signal and an oil filter blockage signal;
when the equipment early warning signal is an operation early warning signal, controlling an alarm lamp to flicker orange for early warning, and simultaneously displaying the content of the operation early warning signal by a display screen; when the equipment early warning signal is an equipment maintenance signal, controlling an alarm lamp to flash yellow to give an alarm, and simultaneously displaying the content of the equipment maintenance signal by a display screen; when the equipment early warning signal is a maintenance early warning signal, controlling an alarm lamp to flash red for alarming, and simultaneously displaying the maintenance early warning signal on a display screen;
when the flashing time of the alarm lamp reaches T3 seconds, dispatching a worker through the administrator module; wherein T3 is a preset time coefficient; when the flashing time of the alarm lamp does not reach T3 seconds, sending the flashing record of the alarm lamp to a data storage module for storage; the alarm lamp flashing record comprises the flashing color of the alarm lamp and the flashing duration of the alarm lamp.
Further, the specific steps of the administrator module dispatching the staff include:
acquiring a duty list through a data storage module; the name, the mobile phone number, the work age and the dispatching times of the staff on the duty list, wherein the staff comprises operation staff and equipment staff;
acquiring the work age and dispatching times of workers, and respectively marking the work age and the dispatching times as GL and PC;
acquiring a worker evaluation coefficient GPX through a formula GPX of gamma 1 × GL + gamma 2 × PC + gamma 3; wherein gamma 1, gamma 2 and gamma 3 are preset proportionality coefficients, and gamma 1, gamma 2 and gamma 3 are real numbers greater than 0;
performing descending arrangement on the worker evaluation coefficients GPX, and respectively acquiring an operation worker sequencing list and an equipment worker sequencing list;
separating the front N1 bits of the operation staff sequencing list to generate a first operation staff list, and generating a second operation staff list by the rest part of the operation staff sequencing list; separating the front N1 bits of the equipment staff sequencing list and generating a second equipment staff list, wherein the rest part of the equipment staff sequencing list generates the second equipment staff list;
when the administrator module receives an operation early warning signal, dispatching a first worker group to check the operation process of the high-efficiency compressor, wherein the first worker group respectively selects one worker from a first operation worker table and a second operation worker table; when the administrator receives the equipment maintenance signal, dispatching a second staff group to check the high-efficiency compressor body, wherein the second staff group respectively selects one staff from the first equipment staff table and the second equipment staff table; when the administrator receives the maintenance early warning signal, sending a third staff group to maintain the high-efficiency compressor body and the operation process of the high-efficiency compressor body, wherein the third staff group respectively selects one staff from the first operation staff table and the first equipment staff table;
and sending the dispatching records of the first staff group, the second staff group and the third staff group to a data storage module for storage.
Further, the operation monitoring system is used for monitoring the operation process of the high-efficiency compressor and giving an early warning to faults in the operation process, and comprises the following steps:
acquiring the moment of the high-efficiency compressor in real time, and marking the moment as LJ; when the moment LJ meets 0< LJ is less than or equal to K1, the moment of the high-efficiency compressor is judged to be low moment; when the torque LJ meets K2< LJ, the torque of the high-efficiency compressor is judged to be high torque; wherein K1 and K2 are preset torque thresholds, and K1< K2;
acquiring the height of a deposition zone in the high-efficiency compressor in real time, and marking the height of the deposition zone as CDG; when the height CDG of the deposition zone satisfies 0< CDG ≦ K3, determining that the deposition zone is a low deposition zone; when the deposition zone height CDG satisfies K4< CDG, then determining that the deposition zone is a high deposition zone; wherein K3 and K4 are preset deposition zone height thresholds, and K3< K4;
when the moment LJ and the height CDG of the deposition zone meet the conditions that 0< LJ is not more than K1 and 0< CDG is not more than K2 at the same time, judging that the feeding of the efficient compressor is abnormal, and sending a feeding abnormal signal to the administrator module through the processor;
when the moment LJ and the height CDG of the sedimentary belt meet 0< LJ ≤ K1 and K3< CDG at the same time, determining that the efficient compressor is under flocculated, and sending a signal of the under flocculated to the administrator module through the processor;
when the moment LJ and the height CDG of the sedimentary belt simultaneously meet K2< LJ and 0< CDG < K3, judging that the efficient compressor is over-flocculated, and sending an over-flocculated signal to an administrator module through the processor;
when the moment LJ and the height CDG of the deposition zone meet K2< LJ and K4< CDG at the same time, judging that the underflow pump of the efficient compressor is abnormal, and sending an abnormal underflow pump signal to an administrator module through a processor;
and sending the torque and the height of the deposition zone to a data storage module for storage through a processor.
Further, the monitoring process of the conventional monitoring module includes:
acquiring the oil level of the speed reducer by an oil level sensor every T1 time, acquiring the ratio of the oil level of the speed reducer to the height of an oil tank of the speed reducer, recording the ratio as the oil level scale of the speed reducer, and marking the oil level scale of the speed reducer as JYK; wherein T1 is a preset time threshold;
acquiring the oil level of the hydraulic machine by an oil level sensor at intervals of T1, acquiring the ratio of the oil level of the hydraulic machine to the height of an oil tank of the hydraulic machine, recording the ratio as oil level scales of the hydraulic machine, and marking the oil level scales of the hydraulic machine as YYK;
acquiring an oil evaluation coefficient YPX through a formula YPX of alpha 1 XJYK X YYK; wherein alpha 1 is a preset proportionality coefficient, and alpha 1 belongs to [0.95,1.05 ];
when the oil evaluation coefficient YPX meets the condition that YPX is not less than 0 and not more than L1, judging that the oil level of the efficient compressor is abnormal, and sending an oil level abnormal signal to an administrator module through the processor; when the oil evaluation coefficient YPX meets L1< YPX, the oil level of the high-efficiency compressor is judged to be normal, and an oil level normal signal is sent to the administrator module through the processor; wherein L1 is a preset oil evaluation coefficient threshold;
monitoring leakage of an oil way in the high-efficiency thickener in real time, and marking a leakage monitoring result as YX; the value of the leakage monitoring result YX is 0 and 1, when YX is 1, the leakage of the oil way of the high-efficiency concentrator is shown, an oil way leakage signal is sent to the administrator module through the processor, and when YX is 0, the leakage of the oil way of the high-efficiency concentrator is not shown;
acquiring a pressure value between the rake and the slideway at intervals of T2, and marking the pressure value as TY; wherein T2 is a preset time threshold, and T1< T2; when the pressure value TY satisfies TY > L2, the slide way is judged to be lack of lubricating oil, and a lubricating oil shortage signal is sent to the administrator module; wherein L2 is a preset pressure value threshold;
acquiring the pressure difference of two sides of the hydraulic oil filter at intervals of T2, and marking the oil filter pressure difference as YYC; when the oil filter pressure difference YYC is greater than L3, judging that the hydraulic oil filter is blocked, and sending an oil filter blocking signal to the administrator module through the processor; wherein L3 is a preset oil filtration pressure difference threshold value;
by the formula
Obtaining a maintenance evaluation coefficient JPX; wherein alpha 2 and alpha 3 are preset proportionality coefficients, and both alpha 2 and alpha 3 are real numbers larger than 0;
when the maintenance evaluation coefficient JPX meets the condition that 0 is not less than JPX < L4, the efficient compressor is judged to need maintenance, and a maintenance early warning signal is sent to the administrator module through the processor; wherein L4 is a preset maintenance evaluation coefficient threshold;
and sending the oil evaluation coefficient, the leakage monitoring result, the pressure value and the oil filter pressure difference to a data storage module for storage.
The above formulas are all calculated by removing dimensions and taking values thereof, the formula is one closest to the real situation obtained by collecting a large amount of data and performing software simulation, and the preset parameters in the formula are set by the technical personnel in the field according to the actual situation.
The working principle of the invention is as follows:
acquiring the moment LJ of the high-efficiency compressor in real time; when the moment LJ meets 0< LJ is less than or equal to K1, the moment of the high-efficiency compressor is judged to be low moment; when the torque LJ meets K2< LJ, the torque of the high-efficiency compressor is judged to be high torque; acquiring the height CDG of a deposition zone in the high-efficiency compressor in real time; when the height CDG of the deposition zone satisfies 0< CDG ≦ K3, determining that the deposition zone is a low deposition zone; when the deposition zone height CDG satisfies K4< CDG, then determining that the deposition zone is a high deposition zone; when the moment LJ and the height CDG of the deposition zone meet the conditions that 0< LJ is not more than K1 and 0< CDG is not more than K2 at the same time, judging that the feeding of the efficient compressor is abnormal, and sending a feeding abnormal signal to the administrator module through the processor; when the moment LJ and the height CDG of the sedimentary belt meet 0< LJ ≤ K1 and K3< CDG at the same time, determining that the efficient compressor is under flocculated, and sending a signal of the under flocculated to the administrator module through the processor; when the moment LJ and the height CDG of the sedimentary belt simultaneously meet K2< LJ and 0< CDG < K3, judging that the efficient compressor is over-flocculated, and sending an over-flocculated signal to an administrator module through the processor; when the moment LJ and the height CDG of the deposition zone meet K2< LJ and K4< CDG at the same time, judging that the underflow pump of the efficient compressor is abnormal, and sending an abnormal underflow pump signal to an administrator module through a processor;
acquiring the oil level of the speed reducer by an oil level sensor every T1 time, acquiring the ratio of the oil level of the speed reducer to the height of an oil tank of the speed reducer, and recording the ratio as speed reducer oil level scale JYK; acquiring the oil level of the hydraulic machine by an oil level sensor at intervals of T1, acquiring the ratio of the oil level of the hydraulic machine to the height of an oil tank of the hydraulic machine, recording the ratio as oil level scales of the hydraulic machine, and marking the oil level scales of the hydraulic machine as YYK; acquiring an oil evaluation coefficient YPX; when the oil evaluation coefficient YPX meets the condition that YPX is not less than 0 and not more than L1, judging that the oil level of the efficient compressor is abnormal, and sending an oil level abnormal signal to an administrator module through the processor; when the oil evaluation coefficient YPX meets L1< YPX, the oil level of the high-efficiency compressor is judged to be normal, and an oil level normal signal is sent to the administrator module through the processor; monitoring leakage of an oil way in the high-efficiency thickener in real time, and marking a leakage monitoring result as YX; acquiring a pressure value between the rake and the slideway at intervals of T2, and marking the pressure value as TY; wherein T2 is a preset time threshold, and T1< T2; when the pressure value TY satisfies TY > L2, the slide way is judged to be lack of lubricating oil, and a lubricating oil shortage signal is sent to the administrator module; acquiring the pressure difference of two sides of the hydraulic oil filter at intervals of T2, and marking the oil filter pressure difference as YYC; when the oil filter pressure difference YYC is greater than L3, judging that the hydraulic oil filter is blocked, and sending an oil filter blocking signal to the administrator module through the processor; obtaining a maintenance evaluation coefficient JPX; when the maintenance evaluation coefficient JPX meets the condition that 0 is not less than JPX < L4, the efficient compressor is judged to need maintenance, and a maintenance early warning signal is sent to the administrator module through the processor;
the administrator module analyzes the received equipment early warning signal sent by the processor; the administrator module comprises an alarm lamp and a display screen; when the equipment early warning signal is an operation early warning signal, controlling an alarm lamp to flicker orange for early warning, and simultaneously displaying the content of the operation early warning signal by a display screen; when the equipment early warning signal is an equipment maintenance signal, controlling an alarm lamp to flash yellow to give an alarm, and simultaneously displaying the content of the equipment maintenance signal by a display screen; when the equipment early warning signal is a maintenance early warning signal, controlling an alarm lamp to flash red for alarming, and simultaneously displaying the maintenance early warning signal on a display screen; when the flashing time of the alarm lamp reaches T3 seconds, dispatching a worker through the administrator module; wherein T3 is a preset time coefficient; when the flashing time of the alarm lamp does not reach T3 seconds, the flashing record of the alarm lamp is sent to the data storage module for storage.
In the description herein, references to the description of "one embodiment," "an example," "a specific example" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The foregoing is merely exemplary and illustrative of the present invention and various modifications, additions and substitutions may be made by those skilled in the art to the specific embodiments described without departing from the scope of the invention as defined in the following claims.
Claims (5)
1. The system for monitoring the operation of the high-efficiency concentrator is characterized by comprising a high-efficiency compressor body and a monitoring system; the high-efficiency compressor body is in communication connection with a monitoring system;
the high-efficiency compressor body comprises a concentration tank, a rake frame lifting device and a feeding device; the monitoring system comprises a processor, an administrator module, a data storage module, an operation monitoring module and a fault detection module; the processor is respectively in communication connection with the administrator module, the data storage module, the operation monitoring module and the conventional monitoring module; the administrator module is in communication connection with the data storage module;
the conventional monitoring module is used for monitoring conventional parameters and a shutdown process of the high-efficiency compressor;
the operation monitoring module is used for early warning and removing faults in the operation process of the high-efficiency compressor;
the intelligent terminal comprises a manager module, a staff and an intelligent terminal, wherein the manager module is used for receiving an equipment early warning signal to perform early warning and dispatching the staff to perform troubleshooting, the manager module is linearly connected with the intelligent terminal of the staff, and the intelligent terminal comprises an intelligent mobile phone, a tablet personal computer and a notebook computer.
2. The system of claim 1, wherein the step of receiving the equipment warning signal by the manager module to warn and dispatch personnel comprises:
the administrator module analyzes the received equipment early warning signal sent by the processor; the administrator module comprises an alarm lamp and a display screen; the equipment early warning signal comprises an operation early warning signal, an equipment maintenance signal and a maintenance early warning signal;
when the equipment early warning signal is an operation early warning signal, controlling an alarm lamp to flicker orange for early warning, and simultaneously displaying the content of the operation early warning signal by a display screen; when the equipment early warning signal is an equipment maintenance signal, controlling an alarm lamp to flash yellow to give an alarm, and simultaneously displaying the content of the equipment maintenance signal by a display screen; when the equipment early warning signal is a maintenance early warning signal, controlling an alarm lamp to flash red for alarming, and simultaneously displaying the maintenance early warning signal on a display screen;
when the flashing time of the alarm lamp reaches T3 seconds, dispatching a worker through the administrator module; wherein T3 is a preset time coefficient; when the flashing time of the alarm lamp does not reach T3 seconds, sending the flashing record of the alarm lamp to a data storage module for storage; the alarm lamp flashing record comprises the flashing color of the alarm lamp and the flashing duration of the alarm lamp.
3. A high efficiency concentrator operation monitoring system as claimed in claim 2 wherein the specific steps of the supervisor module dispatching a worker include:
acquiring a duty list through a data storage module; the name, the mobile phone number, the work age and the dispatching times of the staff of the duty table, wherein the staff comprises operation staff and equipment staff;
acquiring the work age and dispatching times of workers, and respectively marking the work age and the dispatching times as GL and PC;
acquiring a worker evaluation coefficient GPX through a formula GPX of gamma 1 × GL + gamma 2 × PC + gamma 3; wherein gamma 1, gamma 2 and gamma 3 are preset proportionality coefficients, and gamma 1, gamma 2 and gamma 3 are real numbers greater than 0;
performing descending arrangement on the worker evaluation coefficients GPX, and respectively acquiring an operation worker sequencing list and an equipment worker sequencing list;
separating the front N1 bits of the operation staff sequencing list to generate a first operation staff list, and generating a second operation staff list by the rest part of the operation staff sequencing list; separating the front N1 bits of the equipment staff sequencing list and generating a second equipment staff list, wherein the rest part of the equipment staff sequencing list generates the second equipment staff list;
when the administrator module receives an operation early warning signal, sending a first worker group to check the operation process of the high-efficiency compressor; when the administrator receives the equipment maintenance signal, sending a second staff member to inspect the high-efficiency compressor body; when the administrator receives the maintenance early warning signal, sending a third working personnel group to maintain the high-efficiency compressor body and the operation process of the high-efficiency compressor body;
and sending the dispatching records of the first staff group, the second staff group and the third staff group to a data storage module for storage.
4. The system of claim 1, wherein the operation monitoring system is configured to monitor the operation of the high efficiency compressor and provide early warning of faults during operation, and comprises:
acquiring the moment of the high-efficiency compressor in real time, and marking the moment as LJ; when the moment LJ meets 0< LJ is less than or equal to K1, the moment of the high-efficiency compressor is judged to be low moment; when the torque LJ meets K2< LJ, the torque of the high-efficiency compressor is judged to be high torque; wherein K1 and K2 are preset torque thresholds, and K1< K2;
acquiring the height of a deposition zone in the high-efficiency compressor in real time, and marking the height of the deposition zone as CDG; when the height CDG of the deposition zone satisfies 0< CDG ≦ K3, determining that the deposition zone is a low deposition zone; when the deposition zone height CDG satisfies K4< CDG, then determining that the deposition zone is a high deposition zone; wherein K3 and K4 are preset deposition zone height thresholds, and K3< K4;
when the moment LJ and the height CDG of the deposition zone meet the conditions that 0< LJ is not more than K1 and 0< CDG is not more than K2 at the same time, judging that the feeding of the efficient compressor is abnormal, and sending a feeding abnormal signal to the administrator module through the processor;
when the moment LJ and the height CDG of the sedimentary belt meet 0< LJ ≤ K1 and K3< CDG at the same time, determining that the efficient compressor is under flocculated, and sending a signal of the under flocculated to the administrator module through the processor;
when the moment LJ and the height CDG of the sedimentary belt simultaneously meet K2< LJ and 0< CDG < K3, judging that the efficient compressor is over-flocculated, and sending an over-flocculated signal to an administrator module through the processor;
when the moment LJ and the height CDG of the deposition zone meet K2< LJ and K4< CDG at the same time, judging that the underflow pump of the efficient compressor is abnormal, and sending an abnormal underflow pump signal to an administrator module through a processor;
and sending the torque and the height of the deposition zone to a data storage module for storage through a processor.
5. A high efficiency concentrator operation monitoring system as in claim 1 wherein the monitoring process of the conventional monitoring module comprises:
acquiring the oil level of the speed reducer by an oil level sensor every T1 time, acquiring the ratio of the oil level of the speed reducer to the height of an oil tank of the speed reducer, recording the ratio as the oil level scale of the speed reducer, and marking the oil level scale of the speed reducer as JYK; wherein T1 is a preset time threshold;
acquiring the oil level of the hydraulic machine by an oil level sensor at intervals of T1, acquiring the ratio of the oil level of the hydraulic machine to the height of an oil tank of the hydraulic machine, recording the ratio as oil level scales of the hydraulic machine, and marking the oil level scales of the hydraulic machine as YYK;
acquiring an oil evaluation coefficient YPX through a formula YPX of alpha 1 XJYK X YYK; wherein alpha 1 is a preset proportionality coefficient, and alpha 1 belongs to [0.95,1.05 ];
when the oil evaluation coefficient YPX meets the condition that YPX is not less than 0 and not more than L1, judging that the oil level of the efficient compressor is abnormal, and sending an oil level abnormal signal to an administrator module through the processor; when the oil evaluation coefficient YPX meets L1< YPX, the oil level of the high-efficiency compressor is judged to be normal, and an oil level normal signal is sent to the administrator module through the processor; wherein L1 is a preset oil evaluation coefficient threshold;
monitoring leakage of an oil way in the high-efficiency thickener in real time, and marking a leakage monitoring result as YX; the leakage monitoring result YX takes values of 0 and 1, when YX is 1, the leakage of the oil path of the high-efficiency concentrator is shown, an oil path leakage signal is sent to the administrator module through the processor, and when YX is 0, the leakage of the oil path of the high-efficiency concentrator is not shown;
acquiring a pressure value between the rake and the slideway at intervals of T2, and marking the pressure value as TY; wherein T2 is a preset time threshold, and T1< T2; when the pressure value TY satisfies TY > L2, the slide way is judged to be lack of lubricating oil, and a lubricating oil shortage signal is sent to the administrator module; wherein L2 is a preset pressure value threshold;
acquiring the pressure difference of two sides of the hydraulic oil filter at intervals of T2, and marking the oil filter pressure difference as YYC; when the oil filter pressure difference YYC is greater than L3, judging that the hydraulic oil filter is blocked, and sending an oil filter blocking signal to the administrator module through the processor; wherein L3 is a preset oil filtration pressure difference threshold value;
by the formula
Obtaining a maintenance evaluation coefficient JPX; wherein alpha 2 and alpha 3 are preset proportionality coefficients, and both alpha 2 and alpha 3 are real numbers larger than 0;
when the maintenance evaluation coefficient JPX meets the condition that 0 is not less than JPX < L4, the efficient compressor is judged to need maintenance, and a maintenance early warning signal is sent to the administrator module through the processor; wherein L4 is a preset maintenance evaluation coefficient threshold;
and sending the oil evaluation coefficient, the leakage monitoring result, the pressure value and the oil filter pressure difference to a data storage module for storage.
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