CN112611532B - Intelligent fault diagnosis device and method for vibrating screen - Google Patents
Intelligent fault diagnosis device and method for vibrating screen Download PDFInfo
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- G01M7/00—Vibration-testing of structures; Shock-testing of structures
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Abstract
The invention discloses a vibrating screen fault intelligent diagnosis device and a vibrating screen fault intelligent diagnosis method using the same. According to the invention, through the acquisition of the attitude data and the vibration data, the subsequent fault diagnosis result is more accurate, the fault of the key component in the vibrating screen can be diagnosed more comprehensively and earlier, and the production and equipment loss caused by the damage of the component is reduced.
Description
Technical Field
The invention relates to fault diagnosis equipment and a corresponding diagnosis method thereof, in particular to a vibrating screen fault intelligent diagnosis device and a diagnosis method, and belongs to the technical field of industrial internet.
Background
In the ore dressing industry, a vibrating screen is a common and very critical device, and in terms of the working principle of the vibrating screen, the vibrating screen mainly drives a screen box to do reciprocating motion through a vibration exciter so as to realize screening of materials.
Due to the particularity of the operation scene of the mineral separation industry, in the actual application process, the vibrating screen is in a load operation state for a long time, and faults such as screen abrasion, fixing bolt fracture, shock insulation spring fracture and bearing damage easily occur, so that the screening efficiency is greatly reduced, the operation process is influenced, and the vibrating screen needs to be maintained and replaced when the faults are serious. In addition, the vibrating screen is generally installed in a working environment with serious dust, and the daily state detection and maintenance cannot be carried out by adopting a frequent point inspection mode of a maintainer like other industrial equipment. For the above reasons, how to implement fault diagnosis for the vibrating screen becomes a common concern in the industry.
At present, vibration analysis is a common and mature analysis method for fault diagnosis of rotary equipment or rotating transmission parts in the equipment. Specifically, the vibration analysis is to install a vibration sensor at a motor, a reduction box, a bearing seat and other parts of the equipment, collect vibration signals of the equipment and the like, and analyze the signals by using a digital signal processing technology, so as to diagnose possible causes of equipment faults. However, even if a non-rotating component such as a vibrating screen is out of order, the vibration signal may be abnormal, and due to the lack of a corresponding diagnosis model and algorithm, the equipment cannot be accurately diagnosed by using the existing vibration analysis.
The patent CN102494882B discloses an online monitoring and fault diagnosis device and method for a spring of a mining vibrating screen. In a practical application scene, acceleration data is influenced by factors such as load and exciting force, so that although the scheme can achieve a certain diagnosis effect, the accuracy of the monitored data and the diagnosis result is difficult to ensure because the acceleration data only monitors the acceleration of the spring part of the vibrating screen. In addition, potential faults such as phase changes caused by screen damage and the like are difficult to be accurately diagnosed by the scheme.
In summary, how to provide a fully new vibrating screen fault diagnosis device and a corresponding diagnosis method based on the prior art, the intellectualization degree of the scheme is improved as much as possible on the premise of ensuring the accuracy of the diagnosis result, so that the fault diagnosis of the vibrating screen equipment is realized efficiently, flexibly and at least cost, and the problem to be solved by technical personnel in the field is also solved urgently.
Disclosure of Invention
In view of the above defects in the prior art, the invention provides an intelligent diagnosis device and a diagnosis method for a vibrating screen fault, which are as follows.
An intelligent fault diagnosis device for a vibrating screen comprises an equipment hardware part and a diagnosis processing part,
the hardware part of the equipment comprises a plurality of data collectors for collecting and uploading attitude data and vibration data, each data collector is fixedly arranged on a tested vibration sieve,
the hardware part of the equipment also comprises at least one host used for receiving attitude data and vibration data and completing fault diagnosis, and each host is respectively in signal connection with the data collectors;
the diagnosis processing part comprises a data acquisition module integrated in the data acquisition unit, the data acquisition unit acquires and uploads attitude data and vibration data by means of the data acquisition module,
the diagnosis processing part also comprises a host module integrated in the host, and the host receives and processes the attitude data and the vibration data by means of the host module.
Preferably, each data collector comprises a plurality of wired vibration sensors which are fixedly arranged at monitoring point positions on the tested vibrating screen and are used for collecting and transmitting vibration data of the tested vibrating screen,
each data collector also comprises a data collector main body which is fixedly arranged at the position of a vibration exciter of the tested vibrating screen and is used for collecting and preprocessing the attitude data of the tested vibrating screen and receiving and forwarding the vibration data of the tested vibrating screen;
the data acquisition unit main part includes a 6 inertia measuring unit and a little the control unit, 6 inertia measuring unit with electric connection between the little the control unit, every the wired vibration sensor all with the help of an analog to digital converter with signal connection between the little the control unit.
Preferably, each host comprises a main chip unit for receiving the attitude data of the tested vibrating screen and the vibration data of the tested vibrating screen, performing diagnostic analysis to obtain a diagnostic analysis result and a vibration pattern and outputting the diagnostic analysis result and the vibration pattern,
each host machine also comprises a data storage unit which is used for recording and storing the attitude data of the tested vibrating screen, the vibration data of the tested vibrating screen and the diagnosis and analysis result,
each host machine also comprises a human-computer interaction unit which is used for displaying the diagnosis and analysis result and the vibration graph and supporting the setting of each unit in the host machine through manual operation,
each host machine also comprises a power supply unit used for supplying power to each electrical unit in the device;
data storage unit, human-computer interaction unit and power supply unit equally divide respectively with main chip unit electric connection, every little the control unit all with the help of a communication interface with signal connection between the main chip unit, every little the control unit still respectively with power supply unit electric connection, main chip unit still electric connection has the audible-visual annunciator that is used for sending out audible-visual annunciator when being surveyed the shale shaker and break down.
Preferably, the data acquisition module is integrated in the micro control unit, and includes:
the data acquisition module is used for controlling corresponding hardware to finish acquisition of attitude data of the tested vibrating screen and vibration data of the tested vibrating screen;
the attitude data preprocessing module is used for carrying out primary processing on the attitude data of the tested vibrating screen from the data acquisition module and converting the attitude data of the tested vibrating screen into continuous angular velocity, angular displacement, angular phase, linear velocity, linear displacement and linear phase data;
and the data output module is used for outputting the vibration data of the tested vibrating screen from the data acquisition module and the primarily processed posture data of the tested vibrating screen from the posture data preprocessing module.
Preferably, the data acquisition module comprises a vibration data acquisition sub-module for simultaneously acquiring vibration data of the raw vibrating screen under test from a plurality of the wired vibration sensors,
the data acquisition module also comprises a posture data acquisition submodule for acquiring the posture data of the original tested vibration screen from the data acquisition device main body;
the data output module comprises a vibration data output submodule for receiving the vibration data of the original tested vibration sieve, converting the vibration data into acceleration data, adding a data information head and then transmitting the data to the host module,
the data output module also comprises a posture data output submodule which is used for receiving the preliminarily processed posture data of the tested vibration screen, adding a data information head and then transmitting the data to the host module;
the vibration data acquisition submodule is electrically connected with the vibration data output submodule, and the attitude data acquisition submodule is electrically connected with the attitude data output submodule by means of the attitude data preprocessing module.
Preferably, the host module is integrated in the main chip unit, and includes:
the parameter setting module is used for setting and storing necessary parameters in the fault diagnosis process of the vibrating screen;
the data input module is used for receiving the vibration data of the tested vibration screen from the data output module and the primarily processed attitude data of the tested vibration screen;
the data processing module is used for storing the vibration data of the tested vibration screen and the primarily processed attitude data of the tested vibration screen into the data storage unit, executing corresponding data processing operation and generating a data processing result;
the digital signal processing module is used for processing the vibration data of the tested vibration screen and the primarily processed attitude data of the tested vibration screen in cooperation with the data processing module;
the fault diagnosis module is used for carrying out diagnosis analysis operation on the data processing result from the data processing module and generating a diagnosis analysis result;
and the diagnosis output module is used for locally or remotely outputting the diagnosis analysis result and the alarm from the fault diagnosis module.
Preferably, the data input module includes a vibration data input submodule for receiving vibration data of the tested vibration sieve from the vibration data output submodule, and packaging and sending the received vibration data of the tested vibration sieve,
the data input module also comprises an attitude data input submodule for receiving the attitude data of the tested vibration sieve from the attitude data output submodule and packaging the received attitude data of the tested vibration sieve for transmission;
the data processing module comprises a vibration data processing submodule for receiving vibration data of the tested vibration sieve from the vibration data input submodule, storing the data in the data storage unit, calling the digital signal processing module to process the vibration data of the tested vibration sieve and generate a vibration data processing result,
the data processing module also comprises an attitude data processing submodule for receiving attitude data of the tested vibration sieve from the attitude data input submodule, storing the data into the data storage unit, and calling the digital signal processing module to process the attitude data of the tested vibration sieve and generate an attitude data processing result;
the fault diagnosis module comprises a vibration data diagnosis submodule and is used for calling the digital signal processing module, combining a vibration data processing result, sequentially carrying out digital filtering, FFT (fast Fourier transform), Hilbert transform and FFT transform again on vibration data of the tested vibration screen, comparing the characteristic frequencies of a bearing, a gear and a shafting by combining necessary parameters in the parameter setting module through an amplitude spectrum and an envelope spectrum of a vibration signal and further diagnosing faults and generating a vibration data diagnosis and analysis result, then storing the vibration data diagnosis and analysis result in the data storage unit and sending the vibration data diagnosis and analysis result to the diagnosis and output module,
the fault diagnosis module also comprises a posture data diagnosis submodule which is used for calling the digital signal processing module, combining a posture data processing result, converting the posture data of the tested vibration screen into a two-dimensional graph, comparing the two-dimensional graph with a historical normal two-dimensional posture graph stored in the data storage unit, diagnosing the fault, generating a posture data diagnosis and analysis result, storing the posture data diagnosis and analysis result into the data storage unit, and sending the posture data diagnosis and analysis result to the diagnosis and output module;
the diagnosis output module comprises a local output submodule for displaying the diagnosis analysis result and alarming in real time on the man-machine interaction module,
the diagnosis and transmission module further comprises a remote output submodule used for uploading all information in the diagnosis process to a cloud-end platform, so that a user can remotely access and look up the information by using a computer or a mobile phone.
Preferably, the data processing module and the fault diagnosis module are respectively in signal connection with the data storage unit; the data processing module and the fault diagnosis module are both electrically connected with the digital signal processing module; the vibration data input submodule, the vibration data processing submodule and the vibration data diagnosis submodule are electrically connected in sequence, and the attitude data input submodule, the attitude data processing submodule and the attitude data diagnosis submodule are electrically connected in sequence; the local output submodule is electrically connected with the human-computer interaction unit and the audible and visual alarm respectively, and the remote output submodule is in signal connection with the Internet or the Internet of things.
The intelligent fault diagnosis method for the vibrating screen comprises the following steps of:
s1, fixedly arranging a data collector at the vibration exciter position of the tested vibration sieve, ensuring that one data collector is arranged at each vibration exciter position, ensuring that a wired vibration sensor on each data collector is arranged at the position to be monitored on the tested vibration sieve, and arranging a host machine to ensure smooth connection between the data collector and the host machine and between the host machine and the Internet or the Internet of things;
s2, starting the host, setting necessary parameters through a man-machine interaction module, controlling the data acquisition unit to start data acquisition immediately by the host, transmitting vibration data of the tested vibrating screen to the host after the vibration data are acquired by the data acquisition unit, and transmitting attitude data of the tested vibrating screen to the host after the attitude data are preprocessed by the data acquisition unit;
s3, the data processing module in the host receives the data, stores the vibration data of the tested vibrating screen and the attitude data of the tested vibrating screen to the designated position in the data storage unit according to the data acquisition time, then respectively calls the vibration data diagnosis submodule and the attitude data diagnosis submodule to calculate and convert the vibration data of the tested vibrating screen and the attitude data of the tested vibrating screen, and then transfers the vibration data and the attitude data to the fault diagnosis module to carry out fault diagnosis;
and S4, after receiving the data, the fault diagnosis module respectively executes corresponding diagnosis operation, generates corresponding diagnosis analysis results and sends the diagnosis analysis results to the diagnosis output module, and the diagnosis output module outputs corresponding information according to the diagnosis analysis results.
Preferably, S4 includes the steps of:
s41, after the fault diagnosis module receives vibration data of the tested vibration screen, the vibration data diagnosis submodule is called to carry out digital filtering, FFT (fast Fourier transform), Hilbert transform and FFT algorithm processing again on the vibration data of the tested vibration screen, and then whether a vibration fault exists in a rotating component in the tested vibration screen is analyzed by combining with a vibration fault model;
after the fault diagnosis module receives the attitude data of the tested vibration sieve, the attitude data diagnosis submodule is called to convert linear data and angle data in the attitude data of the tested vibration sieve into a two-dimensional image, and then whether the sieve body fault exists in the tested vibration sieve is judged according to the image;
s42, the diagnosis output module receives the vibration data diagnosis analysis result, if the result shows that the vibration fault exists in the tested vibration sieve, the fault part, the reason, the time domain parameter and the spectrogram for judging the vibration fault are displayed on the human-computer interaction unit, and if the result shows that the vibration fault does not exist in the tested vibration sieve, the time domain parameter is only displayed;
the diagnosis output module receives a posture data diagnosis analysis result, if the result shows that the tested vibration sieve has a posture fault, the diagnosis output module displays a fault reason, a two-dimensional posture graph and a posture data chart on the human-computer interaction unit, and if the result shows that the tested vibration sieve does not have the posture fault, the diagnosis output module only displays the two-dimensional posture graph and prompts normal characters of the sieve body;
if the tested vibration screen has serious attitude faults and vibration faults, an alarm is sent out, and the alarm is not cleared before the alarm is cleared manually.
Compared with the prior art, the invention has the following advantages:
according to the intelligent diagnosis device and the corresponding diagnosis method for the fault of the vibrating screen, provided by the invention, the 6-axis IMU sensor and the vibrating sensor are comprehensively utilized, the attitude data of the screen body of the vibrating screen is acquired through the 6-axis IMU sensor, and the vibration data of the rotating part in the vibrating screen is acquired through the vibrating sensor, so that the data acquisition amount is large, the coverage is wide, the subsequent fault diagnosis result is more accurate, the fault of the key part in the vibrating screen can be diagnosed more comprehensively and earlier, and the production and equipment loss caused by the damage of the part is reduced.
Meanwhile, in the hardware technical scheme of the invention, the data collectors are wirelessly connected with the host through a network, one host can be connected with a plurality of data collectors and can simultaneously carry out fault diagnosis on a plurality of vibrating screen devices, so that the hardware technical scheme is more suitable for large-scale popularization and application of various factories and mines, and the hardware cost is also obviously reduced.
Moreover, the method and the device also support the uploading of data to an internet cloud platform, provide convenience for a user to remotely check the running state and historical data of the vibrating screen, and provide conditions for the user to perform long-term online diagnosis operation, thereby further expanding the application range of the method and the device.
In addition, the invention has rich application scenes and wide application prospect, provides reference basis for related technologies in the same field, and can be applied to other technical schemes related to fault diagnosis equipment and methods by adaptively adjusting and changing the technical scheme of the invention by technical personnel.
The following detailed description of the embodiments of the present invention is provided in connection with the accompanying drawings for the purpose of facilitating understanding and understanding of the technical solutions of the present invention.
Drawings
FIG. 1 is a block diagram of the hardware components of the apparatus of the present invention;
FIG. 2 is a partial block diagram of the hardware components of the apparatus of the present invention;
FIG. 3 is a block diagram of a host module in the diagnostic processing section of the present invention;
FIG. 4 is a block diagram of the data acquisition module in the diagnostic processing section of the present invention.
Detailed Description
The invention provides a vibrating screen fault intelligent diagnosis device and a vibrating screen fault intelligent diagnosis method, which are as follows.
As shown in fig. 1 to 4, an intelligent diagnosis device for a vibrating screen fault includes an equipment hardware part and a diagnosis processing part.
The device hardware part comprises a plurality of data collectors for collecting and uploading attitude data and vibration data, and each data collector is fixedly arranged on a tested vibration sieve;
the hardware part of the equipment also comprises at least one host used for receiving attitude data and vibration data and completing fault diagnosis, and each host is respectively in signal connection with the data collectors.
The diagnosis processing part comprises a data acquisition module integrated in the data acquisition unit, and the data acquisition unit acquires and uploads attitude data and vibration data by means of the data acquisition module;
the diagnosis processing part also comprises a host module integrated in the host, and the host receives and processes the attitude data and the vibration data by means of the host module.
Each data collector comprises a plurality of wired vibration sensors, is fixedly arranged at the monitoring point position on the tested vibration sieve and is used for collecting and transmitting vibration data of the tested vibration sieve;
each data collector also comprises a data collector main body which is fixedly arranged at the position of the vibration exciter of the tested vibrating screen and is used for collecting and preprocessing the attitude data of the tested vibrating screen and receiving and forwarding the vibration data of the tested vibrating screen.
The data acquisition Unit main body comprises a 6-axis Inertial Measurement Unit (IMU) and a Micro Control Unit (MCU), the 6-axis Inertial Measurement Unit is electrically connected with the MCU, and each wired vibration sensor is in signal connection with the MCU by means of an Analog-to-digital converter (ADC).
In this section, it should be specifically noted that the wired vibration sensor is preferably a pressure-sensitive vibration sensor, but may be replaced by another sensor integrating vibration and temperature, or a wireless sensor having similar functions. The preferred model of the 6-axis inertial measurement unit is the STISM330, which contains 3-axis gravitational acceleration and 3-axis gyroscopes. The preferred model of the micro control unit is STM32F412RG, which runs the FreeRTOS operating system.
Each host comprises a main chip unit which is used for receiving the attitude data of the tested vibrating screen and the vibration data of the tested vibrating screen, carrying out diagnosis and analysis, obtaining a diagnosis and analysis result and a vibration graph and outputting the diagnosis and analysis result and the vibration graph;
each host machine also comprises a data storage unit which is used for recording and storing the attitude data of the tested vibrating screen, the vibration data of the tested vibrating screen and the diagnosis and analysis result;
each host machine also comprises a human-computer interaction unit which is used for displaying the diagnosis and analysis result and the vibration graph and supporting the setting of each unit in the host machine through manual operation;
each of the hosts further comprises a power supply unit for supplying power to each electrical unit in the device.
Data storage unit, human-computer interaction unit and power supply unit equally divide respectively with main chip unit electric connection, every little the control unit all with the help of a communication interface with signal connection between the main chip unit, every little the control unit still respectively with power supply unit electric connection, main chip unit still electric connection has the audible-visual annunciator that is used for sending out audible-visual annunciator when being surveyed the shale shaker and break down.
It should be specifically noted in this section that the master chip unit may run an embedded Linux operating system in order to meet the needs of industrial applications. The data storage unit comprises a DRAM (dynamic random access memory) and a Nand flash memory, wherein the DRAM is preferably a DDR3 DRAM with 4 GByte; and the Nand flash memory is preferably 32GByte and is used for storing solidified embedded software, parameters required by collection and diagnosis, a bearing vibration characteristic frequency database, attitude data and diagnostic data of a vibrating screen and the like. The human-computer interaction unit preferably adopts a 10-inch capacitive touch liquid crystal display screen and is used for inputting part parameters and parameters required by diagnosis of the tested vibration screen and displaying results of intelligent gesture diagnosis and vibration analysis diagnosis and related charts and data. The audible and visual alarm can be a buzzer, an alarm lamp or other parts.
In addition, in this embodiment, the communication interface is preferably an Ethernet (Ethernet) port, and is configured to communicate with the data collector, acquire attitude and vibration data, and control a collection process and parameter setting of the data collector through a control protocol; in the actual application process, if necessary, the Ethernet port can also be accessed to a local area network of a factory and a mine, and the diagnosis result is uploaded to other equipment management or equipment online monitoring platforms; in consideration of the actual application environment, the connection mode using the ethernet network may be replaced by other connection modes such as industrial WIFI and Zigbee.
The data acquisition module is integrated in little the control unit includes:
the data acquisition module is used for controlling corresponding hardware to finish acquisition of attitude data of the tested vibrating screen and vibration data of the tested vibrating screen;
the attitude data preprocessing module is used for carrying out primary processing on the attitude data of the tested vibrating screen from the data acquisition module and converting the attitude data of the tested vibrating screen into continuous angular velocity, angular displacement, angular phase, linear velocity, linear displacement and linear phase data;
and the data output module is used for outputting the vibration data of the tested vibrating screen from the data acquisition module and the primarily processed posture data of the tested vibrating screen from the posture data preprocessing module.
The data acquisition module comprises a vibration data acquisition submodule and is used for simultaneously acquiring vibration data of an original tested vibration screen from a plurality of wired vibration sensors;
the data acquisition module further comprises a posture data acquisition submodule for acquiring the original posture data of the tested vibrating screen from the data acquisition device main body.
The data output module comprises a vibration data output submodule for receiving the voltage value format and the original vibration data of the vibration sieve to be tested and converting the vibration data into m/s 2 Adding a data information head containing information such as a collection timestamp, a sensor name, a data sampling rate, a data length and the like to the acceleration data in a form, and then transmitting the data to the host module by virtue of the communication interface;
the data output module further comprises a posture data output submodule for receiving the preliminarily processed posture data of the tested vibrating screen, adding a data information header containing information such as an acquisition time stamp, a vibrating screen and sensor name, a data sampling rate and a data length on the posture data in a two-dimensional form, and then transmitting the data to the host module by means of the communication interface.
The vibration data acquisition submodule is electrically connected with the vibration data output submodule, and the attitude data acquisition submodule is electrically connected with the attitude data output submodule by means of the attitude data preprocessing module.
The host module is integrated in the main chip unit and comprises:
the parameter setting module is used for setting and storing various static and dynamic necessary parameters in the fault diagnosis process of the vibrating screen;
it is specifically noted in this section that the necessary parameters include a parameter for attitude fault diagnosis and a parameter for vibration fault diagnosis; if a reduction gearbox is arranged in the tested vibrating screen, the necessary parameters also comprise the gear tooth number and the reduction ratio of the reduction gearbox.
The parameters for attitude fault diagnosis comprise the model of the tested vibrating screen, the motor power, the motor rotating speed, the screen surface area, the screen surface specification, the screen pore size, the vibration frequency, the vibration amplitude, the screen surface inclination angle, the sampling rate and the sampling duration of the 6-axis inertia measurement unit and the attitude data alarm threshold;
the parameters for vibration fault diagnosis comprise the type and size of a bearing, the sampling rate and sampling duration of a wired vibration sensor and a vibration data alarm threshold.
The data input module is used for receiving the vibration data of the tested vibration screen from the data output module and the primarily processed attitude data of the tested vibration screen;
the data processing module is used for storing the vibration data of the tested vibration screen and the primarily processed attitude data of the tested vibration screen into the data storage unit, executing corresponding data processing operation and generating a data processing result;
the digital signal processing module is used for processing the vibration data of the tested vibration screen and the primarily processed attitude data of the tested vibration screen in cooperation with the data processing module;
the fault diagnosis module is used for carrying out diagnosis analysis operation on the data processing result from the data processing module and generating a diagnosis analysis result;
and the diagnosis output module is used for locally or remotely outputting the diagnosis analysis result and the alarm from the fault diagnosis module.
The data input module comprises a vibration data input submodule and is used for receiving vibration data of the tested vibration sieve from the vibration data output submodule, and packaging and sending the received vibration data of the tested vibration sieve;
the data input module also comprises an attitude data input submodule for receiving the attitude data of the tested vibration sieve from the attitude data output submodule and packaging the received attitude data of the tested vibration sieve for transmission;
the data processing module comprises a vibration data processing submodule for receiving vibration data of the tested vibration sieve from the vibration data input submodule, storing the data in the data storage unit, calling the digital signal processing module to process the vibration data of the tested vibration sieve and generate a vibration data processing result,
in the process, the vibration data processing submodule performs time domain parameter calculation and fault alarm prejudgment on the acceleration data of the tested vibration screen obtained after the processing, wherein the time domain parameters comprise a speed effective value, a displacement peak value, a kurtosis and the like, and if the parameters exceed a preset threshold value, the follow-up fault diagnosis module operates to automatically diagnose the vibration fault.
The data processing module also comprises an attitude data processing submodule for receiving attitude data of the tested vibration sieve from the attitude data input submodule, storing the data into the data storage unit, and calling the digital signal processing module to process the attitude data of the tested vibration sieve and generate an attitude data processing result;
similarly, the attitude data processing sub-module sends the generated attitude data processing result to the fault diagnosis module for diagnosis. At any time in the process, the user can operate through the man-machine interaction module to obtain historical data, and selects the historical data to carry out intelligent diagnosis on the vibration data and the attitude data.
The fault diagnosis module comprises a vibration data diagnosis submodule and is used for calling the digital signal processing module, combining a vibration data processing result, sequentially carrying out digital filtering, FFT (fast Fourier transform), Hilbert transform and FFT transform again on vibration data of the tested vibration screen, comparing the characteristic frequencies of a bearing, a gear and a shafting by combining necessary parameters in the parameter setting module through an amplitude spectrum and an envelope spectrum of a vibration signal and further diagnosing faults and generating a vibration data diagnosis and analysis result, then storing the vibration data diagnosis and analysis result in the data storage unit and sending the vibration data diagnosis and analysis result to the diagnosis and output module,
the fault diagnosis module also comprises a posture data diagnosis submodule which is used for calling the digital signal processing module, combining a posture data processing result, converting the posture data of the tested vibrating screen into a two-dimensional graph, comparing the two-dimensional graph with a historical normal two-dimensional posture graph stored in the data storage unit, judging whether the posture of the tested vibrating screen is normal or not, further diagnosing the fault, generating a posture data diagnosis and analysis result, storing the posture data diagnosis and analysis result into the data storage unit, and sending the posture data diagnosis and analysis result to the diagnosis output module;
in the above process, after the fault diagnosis module determines that the vibration or attitude fault exists in the tested vibration sieve, the corresponding diagnosis and analysis result, the original related data of the tested vibration sieve and the intermediate data produced in the data processing module are associated and stored in the data storage unit together, so that a user can subsequently query and diagnose again by using the human-computer interaction module at any time.
The diagnosis output module comprises a local output submodule and is used for displaying a diagnosis analysis result and alarming in real time on the man-machine interaction module, wherein the alarming output is used for displaying and outputting specific alarming information and related data charts when posture or vibration early warning exists, and meanwhile, alarming sound is output through an audible and visual alarm if the alarming belongs to a serious level.
The diagnosis and transmission module further comprises a remote output submodule used for uploading all information in the diagnosis process to a cloud-end platform, so that a user can remotely access and look up the information by using a computer or a mobile phone.
The data processing module and the fault diagnosis module are respectively in signal connection with the data storage unit; the data processing module and the fault diagnosis module are both electrically connected with the digital signal processing module; the vibration data input submodule, the vibration data processing submodule and the vibration data diagnosis submodule are electrically connected in sequence, and the attitude data input submodule, the attitude data processing submodule and the attitude data diagnosis submodule are electrically connected in sequence; the local output submodule is electrically connected with the human-computer interaction unit and the audible and visual alarm respectively, and the remote output submodule is in signal connection with the Internet or the Internet of things.
The invention also discloses an intelligent diagnosis method for the fault of the vibrating screen, which uses the intelligent diagnosis device for the fault of the vibrating screen and comprises the following steps:
s1, fixedly arranging a data collector at the vibration exciter position of the tested vibration sieve, ensuring that one data collector is arranged at each vibration exciter position, ensuring that a wired vibration sensor on each data collector is arranged at the position to be monitored on the tested vibration sieve, and arranging a host machine to ensure smooth connection between the data collector and the host machine and between the host machine and the Internet or the Internet of things;
s2, starting the host, setting necessary parameters through a man-machine interaction module, controlling the data acquisition unit to start data acquisition immediately by the host, transmitting vibration data of the tested vibrating screen to the host after the vibration data are acquired by the data acquisition unit, and transmitting attitude data of the tested vibrating screen to the host after the attitude data are preprocessed by the data acquisition unit;
s3, the data processing module in the host receives the data, stores the vibration data of the tested vibrating screen and the attitude data of the tested vibrating screen to the designated position in the data storage unit according to the data acquisition time, then respectively calls the vibration data diagnosis submodule and the attitude data diagnosis submodule to calculate and convert the vibration data of the tested vibrating screen and the attitude data of the tested vibrating screen, and then transfers the vibration data and the attitude data to the fault diagnosis module to carry out fault diagnosis;
and S4, after receiving the data, the fault diagnosis module respectively executes corresponding diagnosis operation, generates corresponding diagnosis analysis results and sends the diagnosis analysis results to the diagnosis output module, and the diagnosis output module outputs corresponding information according to the diagnosis analysis results.
Further, S4 includes the following steps:
s41, after the fault diagnosis module receives vibration data of the tested vibration screen, the vibration data diagnosis submodule is called to carry out digital filtering, FFT (fast Fourier transform), Hilbert transform and FFT algorithm processing again on the vibration data of the tested vibration screen, and then whether a vibration fault exists in a rotating component in the tested vibration screen is analyzed by combining with a vibration fault model;
after the fault diagnosis module receives the attitude data of the tested vibration sieve, the attitude data diagnosis submodule is called to convert linear data and angle data in the attitude data of the tested vibration sieve into a two-dimensional image, and then whether the sieve body fault exists in the tested vibration sieve is judged according to the image;
s42, the diagnosis output module receives the vibration data diagnosis analysis result, if the result shows that the vibration fault exists in the tested vibration sieve, the information such as the fault position, reason, time domain parameters and a spectrogram for judging the vibration fault is displayed on the human-computer interaction unit, and if the result shows that the vibration fault does not exist in the tested vibration sieve, only the time domain parameters are displayed;
the diagnosis output module receives a posture data diagnosis analysis result, if the result shows that the tested vibration sieve has a posture fault, information such as a fault reason, a two-dimensional posture graph, a posture data chart and the like is displayed on the human-computer interaction unit, and if the result shows that the tested vibration sieve does not have the posture fault, only the two-dimensional posture graph is displayed and normal characters of the sieve body are prompted;
if the tested vibration screen has serious attitude faults and vibration faults, an audible and visual alarm gives an alarm, and before the alarm is cleared manually, the alarm sound and the alarm display are not cleared.
It is also necessary to supplement that, if the host is connected to the cloud platform through the internet and the upload parameters are configured, the diagnosis output module can upload the diagnosis analysis result and the original data to the cloud platform, so that the user can conveniently obtain the running state of the tested vibration screen through the browser or the mobile phone App remote diagnosis data.
In summary, the vibrating screen fault intelligent diagnosis device and the corresponding diagnosis method provided by the invention comprehensively utilize the 6-axis IMU sensor and the vibrating sensor, acquire the attitude data of the vibrating screen body through the 6-axis IMU sensor, and acquire the vibration data of the rotating component in the vibrating screen through the vibrating sensor, and have the advantages of large data acquisition amount and wide coverage, so that the subsequent fault diagnosis result is more accurate, the fault of the key component in the vibrating screen can be diagnosed more comprehensively and earlier, and the production and equipment loss caused by component damage is reduced.
Meanwhile, in the hardware technical scheme of the invention, the data collectors are wirelessly connected with the host through a network, one host can be connected with a plurality of data collectors and can simultaneously carry out fault diagnosis on a plurality of vibrating screen devices, so that the hardware technical scheme is more suitable for large-scale popularization and application of various factories and mines, and the hardware cost is also obviously reduced.
Moreover, the method and the device also support the uploading of data to an internet cloud platform, provide convenience for a user to remotely check the running state and historical data of the vibrating screen, and provide conditions for the user to perform long-term online diagnosis operation, thereby further expanding the application range of the method and the device.
In addition, the invention has rich application scenes and wide application prospect, provides reference basis for related technologies in the same field, and can be applied to other technical schemes related to fault diagnosis equipment and methods by adaptively adjusting and changing the technical scheme of the invention by technical personnel.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein, and any reference signs in the claims are not intended to be construed as limiting the claim concerned.
Finally, it should be understood that although the present description refers to embodiments, not every embodiment contains only a single technical solution, and such description is for clarity only, and those skilled in the art should integrate the description, and the technical solutions in the embodiments can be appropriately combined to form other embodiments understood by those skilled in the art.
Claims (9)
1. An intelligent fault diagnosis method for a vibrating screen is characterized in that an intelligent fault diagnosis device for the vibrating screen is applied to carry out fault diagnosis, the intelligent fault diagnosis device for the vibrating screen comprises an equipment hardware part and a diagnosis processing part,
the hardware part of the equipment comprises a plurality of data collectors for collecting and uploading attitude data and vibration data, each data collector is fixedly arranged on a tested vibration sieve,
the hardware part of the equipment also comprises at least one host used for receiving attitude data and vibration data and completing fault diagnosis, and each host is respectively in signal connection with the data collectors;
the diagnosis processing part comprises a data acquisition module integrated in the data acquisition unit, the data acquisition unit acquires and uploads attitude data and vibration data by means of the data acquisition module,
the diagnosis processing part also comprises a host module integrated in the host, and the host receives and processes the attitude data and the vibration data by means of the host module;
the diagnostic method comprises the following steps:
s1, fixedly arranging a data collector at the vibration exciter position of the tested vibration sieve, ensuring that one data collector is arranged at each vibration exciter position, ensuring that a wired vibration sensor on each data collector is arranged at the position to be monitored on the tested vibration sieve, and arranging a host machine to ensure smooth connection between the data collector and the host machine and between the host machine and the Internet or the Internet of things;
s2, starting the host, setting necessary parameters through a man-machine interaction module, controlling the data acquisition unit to start data acquisition immediately by the host, transmitting vibration data of the tested vibrating screen to the host after the vibration data are acquired by the data acquisition unit, and transmitting attitude data of the tested vibrating screen to the host after the attitude data are preprocessed by the data acquisition unit;
s3, the data processing module in the host receives the data, stores the vibration data of the tested vibrating screen and the attitude data of the tested vibrating screen to the designated position in the data storage unit according to the data acquisition time, then respectively calls the vibration data diagnosis submodule and the attitude data diagnosis submodule to calculate and convert the vibration data of the tested vibrating screen and the attitude data of the tested vibrating screen, and then transfers the vibration data and the attitude data to the fault diagnosis module to carry out fault diagnosis;
and S4, after receiving the data, the fault diagnosis module respectively executes corresponding diagnosis operation, generates corresponding diagnosis analysis results and sends the diagnosis analysis results to the diagnosis output module, and the diagnosis output module outputs corresponding information according to the diagnosis analysis results.
2. The intelligent fault diagnosis method for the vibrating screen, according to claim 1, is characterized in that:
each data collector comprises a plurality of wired vibration sensors which are fixedly arranged at the monitoring point position on the tested vibration sieve and are used for collecting and transmitting the vibration data of the tested vibration sieve,
each data collector also comprises a data collector main body which is fixedly arranged at the position of a vibration exciter of the tested vibrating screen and is used for collecting and preprocessing the attitude data of the tested vibrating screen and receiving and forwarding the vibration data of the tested vibrating screen;
the data acquisition unit main part includes a 6 inertia measuring unit and a little the control unit, 6 inertia measuring unit with electric connection between the little the control unit, every the wired vibration sensor all with the help of an analog to digital converter with signal connection between the little the control unit.
3. The intelligent fault diagnosis method for the vibrating screen, according to claim 2, is characterized in that:
each host comprises a main chip unit for receiving the attitude data of the tested vibrating screen and the vibration data of the tested vibrating screen, carrying out diagnosis and analysis to obtain a diagnosis and analysis result and a vibration pattern and outputting the diagnosis and analysis result and the vibration pattern,
each host machine also comprises a data storage unit which is used for recording and storing the attitude data of the tested vibrating screen, the vibration data of the tested vibrating screen and the diagnosis and analysis result,
each host machine also comprises a human-computer interaction unit which is used for displaying the diagnosis and analysis result and the vibration graph and supporting the setting of each unit in the host machine through manual operation,
each host machine also comprises a power supply unit used for supplying power to each electrical unit in the device;
data storage unit, human-computer interaction unit and power supply unit equally divide respectively with main chip unit electric connection, every little the control unit all with the help of a communication interface with signal connection between the main chip unit, every little the control unit still respectively with power supply unit electric connection, main chip unit still electric connection has the audible-visual annunciator that is used for sending out audible-visual annunciator when being surveyed the shale shaker and break down.
4. The intelligent diagnostic method for the fault of the vibrating screen as claimed in claim 3, wherein the data acquisition module is integrated in the micro control unit and comprises:
the data acquisition module is used for controlling corresponding hardware to finish acquisition of attitude data of the tested vibrating screen and vibration data of the tested vibrating screen;
the attitude data preprocessing module is used for carrying out primary processing on the attitude data of the tested vibrating screen from the data acquisition module and converting the attitude data of the tested vibrating screen into continuous angular velocity, angular displacement, angular phase, linear velocity, linear displacement and linear phase data;
and the data output module is used for outputting the vibration data of the tested vibrating screen from the data acquisition module and the primarily processed posture data of the tested vibrating screen from the posture data preprocessing module.
5. The intelligent fault diagnosis method for the vibrating screen, according to claim 4, is characterized in that:
the data acquisition module comprises a vibration data acquisition submodule for simultaneously acquiring vibration data of an original tested vibration sieve from a plurality of wired vibration sensors,
the data acquisition module also comprises a posture data acquisition submodule for acquiring the posture data of the original tested vibration screen from the data acquisition device main body;
the data output module comprises a vibration data output submodule for receiving the vibration data of the original tested vibrating screen, converting the vibration data into acceleration data, adding a data information head and then transmitting the data to the host module,
the data output module also comprises a posture data output submodule which is used for receiving the preliminarily processed posture data of the tested vibration screen, adding a data information head and then transmitting the data to the host module;
the vibration data acquisition submodule is electrically connected with the vibration data output submodule, and the attitude data acquisition submodule is electrically connected with the attitude data output submodule by means of the attitude data preprocessing module.
6. The intelligent diagnosis method for the fault of the vibrating screen as claimed in claim 5, wherein the host module is integrated in the main chip unit and comprises:
the parameter setting module is used for setting and storing necessary parameters in the fault diagnosis process of the vibrating screen;
the data input module is used for receiving the vibration data of the tested vibration screen from the data output module and the primarily processed attitude data of the tested vibration screen;
the data processing module is used for storing the vibration data of the tested vibration screen and the primarily processed attitude data of the tested vibration screen into the data storage unit, executing corresponding data processing operation and generating a data processing result;
the digital signal processing module is used for processing the vibration data of the tested vibration screen and the primarily processed attitude data of the tested vibration screen in cooperation with the data processing module;
the fault diagnosis module is used for carrying out diagnosis analysis operation on the data processing result from the data processing module and generating a diagnosis analysis result;
and the diagnosis output module is used for locally or remotely outputting the diagnosis analysis result and the alarm from the fault diagnosis module.
7. The intelligent fault diagnosis method for the vibrating screen, according to claim 6, is characterized in that:
the data input module comprises a vibration data input submodule for receiving vibration data of the tested vibration sieve from the vibration data output submodule, packaging the received vibration data of the tested vibration sieve and then sending the packaged vibration data,
the data input module also comprises an attitude data input submodule for receiving the attitude data of the tested vibration sieve from the attitude data output submodule and packaging the received attitude data of the tested vibration sieve for transmission;
the data processing module comprises a vibration data processing submodule for receiving vibration data of the tested vibration sieve from the vibration data input submodule, storing the data in the data storage unit, calling the digital signal processing module to process the vibration data of the tested vibration sieve and generate a vibration data processing result,
the data processing module also comprises an attitude data processing submodule for receiving attitude data of the tested vibration sieve from the attitude data input submodule, storing the data into the data storage unit, and calling the digital signal processing module to process the attitude data of the tested vibration sieve and generate an attitude data processing result;
the fault diagnosis module comprises a vibration data diagnosis submodule and is used for calling the digital signal processing module, combining a vibration data processing result, sequentially carrying out digital filtering, FFT (fast Fourier transform), Hilbert transform and FFT transform again on vibration data of the tested vibration screen, comparing the characteristic frequencies of a bearing, a gear and a shafting by combining necessary parameters in the parameter setting module through an amplitude spectrum and an envelope spectrum of a vibration signal and further diagnosing faults and generating a vibration data diagnosis and analysis result, then storing the vibration data diagnosis and analysis result in the data storage unit and sending the vibration data diagnosis and analysis result to the diagnosis and output module,
the fault diagnosis module also comprises a posture data diagnosis submodule which is used for calling the digital signal processing module, combining a posture data processing result, converting the posture data of the tested vibration screen into a two-dimensional graph, comparing the two-dimensional graph with a historical normal two-dimensional posture graph stored in the data storage unit, diagnosing the fault, generating a posture data diagnosis and analysis result, storing the posture data diagnosis and analysis result into the data storage unit, and sending the posture data diagnosis and analysis result to the diagnosis and output module;
the diagnosis output module comprises a local output submodule for displaying the diagnosis analysis result and alarming in real time on the man-machine interaction module,
the diagnosis and transmission module further comprises a remote output submodule used for uploading all information in the diagnosis process to a cloud-end platform, so that a user can remotely access and look up the information by using a computer or a mobile phone.
8. The intelligent fault diagnosis method for the vibrating screen, according to claim 7, is characterized in that: the data processing module and the fault diagnosis module are respectively in signal connection with the data storage unit; the data processing module and the fault diagnosis module are both electrically connected with the digital signal processing module; the vibration data input submodule, the vibration data processing submodule and the vibration data diagnosis submodule are electrically connected in sequence, and the attitude data input submodule, the attitude data processing submodule and the attitude data diagnosis submodule are electrically connected in sequence; the local output submodule is electrically connected with the human-computer interaction unit and the audible and visual alarm respectively, and the remote output submodule is in signal connection with the Internet or the Internet of things.
9. The intelligent diagnosis method for the fault of the vibrating screen as claimed in claim 1, wherein S4 comprises the following steps:
s41, after the fault diagnosis module receives vibration data of the tested vibration screen, the vibration data diagnosis submodule is called to carry out digital filtering, FFT (fast Fourier transform), Hilbert transform and FFT algorithm processing again on the vibration data of the tested vibration screen, and then whether a vibration fault exists in a rotating component in the tested vibration screen is analyzed by combining with a vibration fault model;
after the fault diagnosis module receives the attitude data of the tested vibration sieve, the attitude data diagnosis submodule is called to convert linear data and angle data in the attitude data of the tested vibration sieve into a two-dimensional image, and then whether the sieve body fault exists in the tested vibration sieve is judged according to the image;
s42, the diagnosis output module receives the vibration data diagnosis analysis result, if the result shows that the vibration fault exists in the tested vibration sieve, the fault part, the reason, the time domain parameter and the spectrogram for judging the vibration fault are displayed on the human-computer interaction unit, and if the result shows that the vibration fault does not exist in the tested vibration sieve, the time domain parameter is only displayed;
the diagnosis output module receives a posture data diagnosis analysis result, if the result shows that the tested vibration sieve has a posture fault, the diagnosis output module displays a fault reason, a two-dimensional posture graph and a posture data chart on the human-computer interaction unit, and if the result shows that the tested vibration sieve does not have the posture fault, the diagnosis output module only displays the two-dimensional posture graph and prompts normal characters of the sieve body;
if the tested vibration screen has serious attitude faults and vibration faults, an alarm is sent out, and the alarm is not cleared before the alarm is cleared manually.
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