CN112863543A - Method for monitoring equipment by using sound - Google Patents
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- 238000000034 method Methods 0.000 title claims abstract description 41
- 238000012544 monitoring process Methods 0.000 title claims abstract description 18
- 238000012545 processing Methods 0.000 claims abstract description 59
- 230000008878 coupling Effects 0.000 claims abstract description 43
- 238000010168 coupling process Methods 0.000 claims abstract description 43
- 238000005859 coupling reaction Methods 0.000 claims abstract description 43
- 230000005236 sound signal Effects 0.000 claims abstract description 32
- 230000002159 abnormal effect Effects 0.000 claims abstract description 27
- 230000008569 process Effects 0.000 claims abstract description 18
- 238000007621 cluster analysis Methods 0.000 claims abstract description 6
- 239000011159 matrix material Substances 0.000 claims description 14
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- 230000008859 change Effects 0.000 claims description 10
- 238000013528 artificial neural network Methods 0.000 claims description 3
- 238000000611 regression analysis Methods 0.000 claims description 3
- 238000012806 monitoring device Methods 0.000 claims 3
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- G—PHYSICS
- G10—MUSICAL INSTRUMENTS; ACOUSTICS
- G10L—SPEECH ANALYSIS TECHNIQUES OR SPEECH SYNTHESIS; SPEECH RECOGNITION; SPEECH OR VOICE PROCESSING TECHNIQUES; SPEECH OR AUDIO CODING OR DECODING
- G10L25/00—Speech or voice analysis techniques not restricted to a single one of groups G10L15/00 - G10L21/00
- G10L25/48—Speech or voice analysis techniques not restricted to a single one of groups G10L15/00 - G10L21/00 specially adapted for particular use
- G10L25/51—Speech or voice analysis techniques not restricted to a single one of groups G10L15/00 - G10L21/00 specially adapted for particular use for comparison or discrimination
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- G—PHYSICS
- G10—MUSICAL INSTRUMENTS; ACOUSTICS
- G10L—SPEECH ANALYSIS TECHNIQUES OR SPEECH SYNTHESIS; SPEECH RECOGNITION; SPEECH OR VOICE PROCESSING TECHNIQUES; SPEECH OR AUDIO CODING OR DECODING
- G10L25/00—Speech or voice analysis techniques not restricted to a single one of groups G10L15/00 - G10L21/00
- G10L25/48—Speech or voice analysis techniques not restricted to a single one of groups G10L15/00 - G10L21/00 specially adapted for particular use
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Abstract
The invention provides a method for monitoring equipment by using sound, which comprises the following steps: reading a sound signal of the equipment operation process; subjecting the sound signal to multi-bit signal processing to generate a processed signal; processing the processed signal into a plurality of bandwidth signals through cluster analysis; calculating each bandwidth signal to generate a matrix-type audio index, an impact index and an acoustic coupling index; comparing and analyzing the audio index, the impact index and the acoustic coupling index with the constant speed reference model, judging similarity values between the audio index, the impact index and the acoustic coupling index and the constant speed reference model respectively, and generating a judgment result according to the similarity values; when the judgment result is abnormal, generating a warning signal; therefore, the running state of the equipment is accurately judged.
Description
Technical Field
The present invention relates to the field of equipment monitoring, and more particularly to a method for monitoring equipment by using sound.
Background
In the process of processing a workpiece, a worker must often perform a round-robin check to determine whether the processing machine is abnormal, so as to avoid the influence on the productivity and quality of the workpiece due to the abnormality of the processing machine. For large processing plants with large plants and numerous machines and large processing machines with large machines and complex mechanisms, not only the machine-by-machine inspection or the part-by-part inspection is time-consuming and inconvenient, but also the fault conditions of various processing machines have various types, and how to accurately judge the abnormality of parts and quickly solve the abnormality can be generally done by the experience accumulated over the years.
However, most of the current processing plants rely on the experience of the working personnel for judgment, and once the experience of the working personnel is insufficient or the judgment is wrong, the processing machine is damaged, so that the productivity and the quality of the workpiece are influenced. Therefore, in order to solve the above problems, a plurality of sensors are installed on a processing machine to monitor the operation condition of a machine at any time, but in order to improve the determination accuracy, a sensor needs to be installed on each component of the processing machine to receive a sensing signal of each component and perform a diagnosis, which increases the overall cost of the machine, requires an additional sensor installation procedure, and is also quite high.
Disclosure of Invention
In order to solve the above problems, the present invention provides a method for monitoring equipment by using sound, which judges various abnormal conditions generated during the operation of the equipment by sound, thereby achieving an accurate and effective monitoring effect.
One embodiment of the present invention provides a method of using a sound monitoring apparatus, comprising: a reading step: reading a sound signal of the equipment operation process; a first processing step: processing the sound signal by a multi-bit signal to generate a processed signal; a second processing step: processing the processed signal into a plurality of bandwidth signals through a cluster analysis; an index calculation step: calculating the bandwidth signals to generate an audio index, an impact index and an acoustic coupling index in matrix form; a comparison step: comparing and analyzing the audio index, the impact index and the acoustic coupling index with a constant speed reference model, judging a similarity value between the audio index, the impact index and the acoustic coupling index and the constant speed reference model respectively, and generating a judgment result according to the similarity value; and an alert step: when the judgment result is abnormal, an alarm signal is generated.
In one embodiment, the multi-bit signal processing is processing the sound signal by time-frequency analysis to generate the processed signal having amplitude and frequency corresponding to time.
In one embodiment, the bandwidth signals are processed by frequency calculation to generate the audio indicator in a matrix form.
In one embodiment, the bandwidth signals are processed by kurtosis to generate the hit indicator in a matrix form.
In one embodiment, the bandwidth signals are processed by hilbert transform to generate the acoustic coupling indicator in a matrix form.
In one embodiment, in the comparing step, when the similarity between the audio index, the impact index or the acoustic coupling index and the constant speed reference model is lower than a set similarity and is maintained for a specified time, the judgment result of the index is abnormal and the warning signal is generated; in the warning step, the warning signal is provided and displayed on the terminal device.
In one embodiment, the method further comprises the step of establishing a reference: reading the sound signal of the initial operation process of the equipment; analyzing and processing the sound signal to establish the sound signal as the constant speed reference model through the first processing step, the second processing step and the index calculation step; in the warning step, when any one of the audio index, the impact index or the acoustic coupling index is abnormal, a fault code is established.
In one embodiment, in the reading step, a rotation speed signal of the device during operation is read; performing regression analysis and neural network processing on the rotation speed signal to generate a rotation speed index; in the comparison step, the similarity values between the rotation speed index, the audio index, the impact index and the acoustic coupling index and a speed change reference model are respectively judged to generate the judgment result.
In one embodiment, in the comparing step, when the similarity between the speed index, the audio index, the impact index or the acoustic coupling index and the speed change reference model is lower than a predetermined similarity and is maintained for a predetermined time, the judgment result of the index is abnormal and the warning signal is generated; in the warning step, the warning signal is provided and displayed on the terminal device.
In one embodiment, the method further comprises the step of establishing a reference: reading the sound signal and the rotating speed signal of the initial operation process of the equipment; analyzing and processing the sound signal and the rotating speed signal to establish the sound signal and the rotating speed signal as the speed change reference model through the first processing step, the second processing step and the index calculation step; in the warning step, when any one of the judgment results of the rotation speed index, the audio index, the impact index or the acoustic coupling index is abnormal, a fault code is established.
Through the above, the invention judges various abnormal conditions generated during the operation of the equipment through sound so as to achieve accurate and effective monitoring effect, improve the inaccuracy of the prior art through a manual mode, and reduce the monitoring cost of installing a plurality of sensors additionally.
Moreover, the invention can be suitable for monitoring equipment with fixed rotating speed and variable rotating speed so as to improve the application range of the invention.
Drawings
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
FIG. 1 is a flow chart of a first embodiment of the present invention.
Fig. 2 is a waveform diagram of the sound signal according to the first embodiment of the present invention.
Fig. 3 is a waveform diagram of a processing signal according to the first embodiment of the present invention.
FIG. 4 is a waveform diagram of a first embodiment of the present invention after cluster analysis.
Fig. 5 is a schematic diagram showing an abnormality in the occurrence of an impact index according to the first embodiment of the present invention.
Fig. 6 is a flow chart of a second embodiment of the present invention.
FIG. 7 is a diagram illustrating a rotational speed index according to a second embodiment of the present invention.
Description of the reference numerals
10 sound signal
20 processing signals
30 bandwidth signal
40 audio index
50 rotation speed index
S1 reading step
S2 first processing step
S3 second processing step
S4 index calculation step
S5 reference establishing step
S6 comparison step
S7 warning step.
Detailed Description
To facilitate the explanation of the present invention, the central ideas shown in the above summary are shown in the following embodiments. Various objects in the embodiments are depicted in terms of suitable illustrative proportions, dimensions, deformations, or displacements, rather than in terms of actual components, as previously described.
Referring to fig. 1 to 5, a method for monitoring a constant rotational speed device by using sound is provided according to a first embodiment of the present invention.
The method for monitoring equipment by using sound in the first embodiment of the invention comprises the following steps:
a reading step S1: an audio signal 10 of the device operating process is read by the audio reading device, and the audio signal 10 generates different amplitude intensities in the process along with the operating time of the device, as shown in fig. 2. The sound reading device can be an independent microphone, a built-in microphone of an intelligent mobile device, or a multi-bit recording pen, but the invention is not limited thereto.
A first processing step S2: receiving the audio signal 10 read by the signal reading step S1 through the operation terminal, and performing a multi-bit signal processing on the audio signal 10 by the operation terminal to generate a processed signal 20; wherein the multi-bit signal processing is to process the sound signal 10 by time-frequency analysis to generate a processed signal 20 with amplitude and frequency corresponding to time, as shown in fig. 2 and 3; furthermore, the operation terminal can be a computer terminal or a controller (for example: Microchip PIC32MX series microcontroller), the invention is not limited to this, the operation terminal has a communication function, the operation terminal can be connected with the sound reading device by signal to receive the sound signal 10; the operation terminal can be connected with the cloud server through the internet to transmit information to the cloud server.
A second processing step S3: the operation terminal processes the processed signal 20 processed by the first processing step S2 into a plurality of bandwidth signals 30 through a Cluster Analysis (Cluster Analysis); in the embodiment of the present invention, the computing terminal divides the processed signal 20 into a plurality of fixed bandwidth signals 30 by using a splitting method (clustering Analysis), i.e. one bandwidth signal 30 corresponds to each unit time, as shown in fig. 4.
An index calculation step S4: the operation terminal performs an operation on each bandwidth signal 30 generated by the second processing step S3 to generate an audio indicator 40, an impact indicator and an acoustic coupling indicator in a matrix form, where the audio indicator 40, the impact indicator and the acoustic coupling indicator are respectively used to determine whether each component in the equipment is abnormal, where the audio indicator 40 can be used to determine an abnormal component, for example: whether a motor coil is normal or not, whether a motor bearing is normal or not, whether a stator has an air gap or not, whether a gear is broken or not and the like; the impact indicator can be used to determine abnormal components, such as: the problems that the screw lock assembly and the component are loosened and knocked due to operation and the like are solved; the acoustic coupling index can be used to determine abnormal components, such as: gear eccentricity of the gear box, belt eccentricity, transmission shaft clearance and the like.
Furthermore, in the embodiment of the present invention, the audio indicator 40 is to find whether there is an abnormality in the component through the frequency distribution of each bandwidth signal 30, and the operation terminal generates the audio indicator 40 in a matrix form through the frequency operation of each bandwidth signal 30; the impact index searches whether the component is abnormal or not through the phenomenon of each bandwidth signal 30, and the operation terminal generates the impact index in a matrix form through Kurtosis (Kurtosis) operation on each bandwidth signal 30; the acoustic coupling indicator finds whether the component is abnormal or not through the phenomenon of each bandwidth signal 30, and the operation terminal generates the acoustic coupling indicator in a matrix form through the Hilbert transform (Hilbert transform) operation on each bandwidth signal 30.
A establish reference step S5: when each device initially operates, the sound signal 10 of the initial operation process of the device can be obtained by reading the step S1; then, the audio signal 10 is processed through the first processing step S2, the second processing step S3 and the index calculation step S4 to calculate and obtain the audio index 40, the impact index and the acoustic coupling index when the device is initially operated, and the initial audio index 40, the impact index and the acoustic coupling index are established as a constant speed reference model and stored in the operation terminal.
Furthermore, the constant speed reference model has an audio frequency reference model, an impact reference model and an acoustic coupling reference model, the initial audio index 40 is established as the audio frequency reference model, the initial impact index is established as the impact reference model, and the initial acoustic coupling index is established as the acoustic coupling reference model.
A comparison step S6: after the equipment has established the constant speed reference model, then each time the equipment runs, the audio index 40, the impact index and the acoustic coupling index of the equipment can be obtained through reading step S1, the first processing step S2, the second processing step S3 and the index operation step S4, and the current audio index 40, the impact index and the acoustic coupling index are compared and analyzed with the constant speed reference model through the operation terminal respectively to judge a similarity value between the audio index 40, the impact index and the acoustic coupling index and the constant speed reference model respectively, a judgment result is generated according to the similarity value, wherein when the similarity value between any one of the audio index 40, the impact index or the acoustic coupling index and the constant speed reference model is lower than a set similarity value and is maintained for a designated time, the judgment result of the index is abnormal, and a fault code is established, in the embodiment of the present invention, the similarity value is set to 0.5.
Further explanation is as follows: the operation terminal can preset or provide a similarity value between each set audio index 40, the impact index or the acoustic coupling index and the fixed speed reference model, wherein the operation terminal compares the audio index 40 acquired by the bandwidth signal 30 of each unit time in the operation process of the secondary equipment with the audio reference model to acquire the similarity between the audio index 40 and the audio reference model, and when the similarity between the audio index and the audio reference model is lower than the set similarity value (for example, the set similarity value is 0.5 and the acquired similarity value is 0.4), the judgment result is generated to be 1, and the judgment result is established to be a fault code and stored in the operation terminal for later judgment; otherwise, when the similarity between the two is equal to or higher than the set similarity (for example, the set similarity is 0.5, but the obtained similarity is 0.8), the determination result is 0; by analogy, the impact index and the acoustic coupling index are both determined by the above method.
For example, the following steps are carried out: when the apparatus operates for 10 minutes and the unit time is 1 second, 600 bandwidth signals 30 are calculated to generate audio indicators 40, if each audio indicator 40 is not lower than the audio reference model, the matrix type formed by the judgment results of 600 audio indicators 40 is [0,0, … 0], if one of the audio indicators 40 is lower than the audio reference model, 1 is presented in the judgment result of the corresponding audio indicator 40, and the matrix type formed by the judgment results of 600 audio indicators 40 is [0,0,0,1,0 … 0], and when the time that the audio indicator 40 is lower than the audio reference model is maintained for a specified time (for example, the specified time is 3 minutes, that is, there are 180 continuous judgment results of 1 presented), the judgment result of the audio indicator 40 is determined to be abnormal.
An alert step S7: when one or the combination of the audio index 40, the impact index or the acoustic coupling index is abnormal, the operation terminal will generate a warning signal, and the warning signal will display which index is abnormal; the operation terminal transmits the warning signal to the cloud server, the cloud server provides network signal connection with the terminal device, and the warning signal is displayed on the terminal device, wherein the terminal device can be an intelligent mobile device.
Referring to fig. 6 to 7, a second embodiment of the present invention is different from the previous embodiments in that the apparatus is a variable speed apparatus, and the method for monitoring the apparatus by using sound according to the second embodiment of the present invention further includes:
reading step S1: the equipment is provided with a tachometer, the operation terminal is in signal connection with the tachometer, and the operation terminal can read a tachometer signal in the running process of the equipment through the tachometer.
In the operation process of the equipment, the operation terminal reads the rotation speed signal and obtains the sound signal 10 through the sound reading device, and the sound signal 10 obtains the audio index 40, the impact index and the acoustic coupling index when the equipment is operated through the first processing step S2, the second processing step S3 and the index operation step S4.
Furthermore, in the index calculation step S4, the calculation terminal will perform regression analysis and neural network processing on the rotation speed signal to generate a rotation speed index 50; the rotation speed indicator 50 is used to display the vibration amount generated by sound at each rotation speed, as shown in fig. 7.
Reference establishing step S5: when each device initially operates, the rotation speed signal of the device initial operation process can be obtained through reading the step S1; then, the rotational speed signal is processed by the index processing step S4 to calculate the rotational speed index 50 when the equipment is initially operated, and the initial rotational speed index 50 is established as a speed change reference model and stored in the processing terminal.
Comparison step S6: after the speed change reference model is established, when the equipment runs each time, the rotating speed index 50, the audio index 40, the impact index and the acoustic coupling index of the equipment can be obtained through reading the step S1, the first processing step S2, the second processing step S3 and the index operation step S4, and the rotating speed index 50, the audio index 40, the impact index and the acoustic coupling index of the equipment when the equipment runs are compared and analyzed with the speed change reference model respectively through an operation terminal to judge the similarity value between the rotating speed index 50, the audio index 40, the impact index and the acoustic coupling index and the speed change reference model respectively, and generate a judgment result according to the similarity value, wherein when the similarity value between any one of the rotating speed index 50, the audio index 40, the impact index or the acoustic coupling index and the speed change reference model is lower than the set similarity value and the specified time is maintained, the judgment result of the index is abnormal, and a fault code is established, and in the embodiment of the invention, the similarity value is set to be 0.5.
In summary, the present invention can judge various abnormal conditions generated during the operation of the device by sound, thereby achieving an accurate and effective monitoring effect.
Moreover, the invention can be suitable for monitoring equipment with fixed rotating speed and variable rotating speed so as to improve the use range of the invention.
In addition, the invention can establish fault codes for different abnormal states to provide judgment in the future, can save the judgment operation process and effectively improve the monitoring and judging efficiency.
The above examples are provided only for illustrating the present invention and are not intended to limit the scope of the present invention. It is intended that all such modifications and variations not departing from the spirit of the invention be considered as within the scope of the invention.
Claims (10)
1. A method of monitoring a device using sound, comprising:
a reading step: reading a sound signal of the equipment operation process;
a first processing step: processing the sound signal by a multi-bit signal to generate a processed signal;
a second processing step: processing the processed signal into a plurality of bandwidth signals through a cluster analysis;
an index calculation step: calculating the bandwidth signals to generate an audio index, an impact index and an acoustic coupling index in matrix form;
a comparison step: comparing and analyzing the audio index, the impact index and the acoustic coupling index with a constant speed reference model, judging a similarity value between the audio index, the impact index and the acoustic coupling index and the constant speed reference model respectively, and generating a judgment result according to the similarity value; and
an alarming step: when the judgment result is abnormal, an alarm signal is generated.
2. The method of claim 1, wherein the multi-bit signal processing is processing the audio signal by time-frequency analysis to produce the processed signal having an amplitude and frequency corresponding to time.
3. The method as claimed in claim 1, wherein the bandwidth signals are processed by frequency operation to generate the audio indicator in matrix form.
4. The method of claim 1, wherein the bandwidth signals are processed by kurtosis to generate the impact indicator in a matrix form.
5. The method as claimed in claim 1, wherein the bandwidth signals are processed by Hilbert transform to generate the acoustic coupling indicator in matrix form.
6. The method according to claim 1, wherein in the comparing step, when the similarity between the audio index, the impact index or the acoustic coupling index and the constant velocity reference model is lower than a predetermined similarity and is maintained for a predetermined time, the judgment result of the index is abnormal and the warning signal is generated; in the warning step, the warning signal is provided and displayed on the terminal device.
7. The method of using a sound monitoring device according to claim 1 or 6, further comprising a benchmarking step of: reading the sound signal of the initial operation process of the equipment; analyzing and processing the sound signal to establish the sound signal as the constant speed reference model through the first processing step, the second processing step and the index calculation step; in the warning step, when any one of the audio index, the impact index or the acoustic coupling index is abnormal, a fault code is established.
8. The method of using a sound monitoring device of claim 1, wherein in the reading step, a rotational speed signal of the device during operation is read; performing regression analysis and neural network processing on the rotation speed signal to generate a rotation speed index; in the comparison step, the similarity values between the rotation speed index, the audio index, the impact index and the acoustic coupling index and a speed change reference model are respectively judged to generate the judgment result.
9. The method according to claim 8, wherein in the comparing step, when the similarity between the speed index, the audio index, the impact index or the acoustic coupling index and the shift reference model is lower than a predetermined similarity and is maintained for a predetermined time, the judgment result of the index is abnormal and the warning signal is generated; in the warning step, the warning signal is provided and displayed on the terminal device.
10. A method of using a sound monitoring device according to claim 8 or 9, further comprising a benchmarking step of: reading the sound signal and the rotating speed signal of the initial operation process of the equipment; analyzing and processing the sound signal and the rotating speed signal to establish the sound signal and the rotating speed signal as the speed change reference model through the first processing step, the second processing step and the index calculation step; in the warning step, when any one of the judgment results of the rotating speed index, the audio index, the impact index or the acoustic coupling index is abnormal, a fault code is established.
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