CN112967478A - Equipment expected maintenance early warning system and early warning device thereof - Google Patents
Equipment expected maintenance early warning system and early warning device thereof Download PDFInfo
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- CN112967478A CN112967478A CN202110133790.0A CN202110133790A CN112967478A CN 112967478 A CN112967478 A CN 112967478A CN 202110133790 A CN202110133790 A CN 202110133790A CN 112967478 A CN112967478 A CN 112967478A
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B21/00—Alarms responsive to a single specified undesired or abnormal condition and not otherwise provided for
- G08B21/18—Status alarms
- G08B21/187—Machine fault alarms
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B25/00—Alarm systems in which the location of the alarm condition is signalled to a central station, e.g. fire or police telegraphic systems
- G08B25/01—Alarm systems in which the location of the alarm condition is signalled to a central station, e.g. fire or police telegraphic systems characterised by the transmission medium
- G08B25/10—Alarm systems in which the location of the alarm condition is signalled to a central station, e.g. fire or police telegraphic systems characterised by the transmission medium using wireless transmission systems
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Abstract
The application relates to an equipment anticipatory maintenance early warning system and an early warning device thereof, which relate to the technical field of operation and maintenance and comprise: a sensing module configured to: the device operation information used for detecting the target unit is output; the equipment operation information comprises vibration information, temperature and humidity information and noise information; a pre-processing module connected to the sensing module and configured to: the device is used for analyzing and processing the equipment operation information and outputting the equipment operation information; a gateway module connected to the pre-processing module and configured to: the system comprises a front-stage processing module, a data processing module and a data storage module, wherein the front-stage processing module is used for acquiring equipment operation information output by the front-stage processing module, and performing information interaction, analysis processing and information storage with a preset server; and an interactive terminal connected to the gateway module and/or the server and configured to: the information interaction device is used for carrying out information interaction and displaying the running information of the equipment through the UI interface. This application has more timely discovery equipment trouble and reduces the extravagant effect of manpower.
Description
Technical Field
The application relates to the technical field of operation and maintenance, in particular to an early warning system for expected maintenance of equipment and an early warning device thereof.
Background
Affected by the quality of the product, mechanical devices, such as: a motor; the failure rate and the service life of the device in the using process are different; when mechanical failure occurs, economic loss and safety accident are easy to cause if the failure is not eliminated in time.
In order to solve the above problems, currently, various kinds of mechanical equipment are usually scheduled to be regularly and regularly inspected and maintained by related personnel.
With respect to the related art among the above, the inventors consider that it exists: the failure discovery is not timely and the labor consumption is large.
Disclosure of Invention
In order to find equipment faults more timely and reduce labor waste, the application provides an equipment expected maintenance early warning system and an early warning device thereof.
In a first aspect, the present application provides an apparatus expected maintenance early warning system, which adopts the following technical scheme:
an equipment intended maintenance early warning system comprising:
a sensing module configured to: the device operation information used for detecting the target unit is output; the equipment operation information comprises vibration information, temperature and humidity information and noise information;
a pre-processing module connected to the sensing module and configured to: the device is used for analyzing and processing the equipment operation information and outputting the equipment operation information;
a gateway module connected to the pre-processing module and configured to: the system comprises a front-stage processing module, a data processing module and a data storage module, wherein the front-stage processing module is used for acquiring equipment operation information output by the front-stage processing module, and performing information interaction, analysis processing and information storage with a preset server; and an interactive terminal connected to the gateway module and/or the server and configured to: the information interaction device is used for carrying out information interaction and displaying the running information of the equipment through the UI interface.
Optionally, any one or more of the pre-processing module, the gateway module and the server are configured to: and carrying out early warning analysis processing on the equipment operation information, and outputting an alarm execution instruction if the equipment operation information meets the early warning execution condition.
Optionally, the early warning analysis processing includes determining whether the device operation information exceeds any one or more of a preset vibration frequency/amplitude threshold, a noise threshold, a temperature threshold, and a humidity threshold.
Optionally, the pre-stage processing module is further configured to: outputting a standby machine starting control instruction to a preset standby machine according to a preset standby machine starting condition; wherein, the standby machine starting condition comprises that the equipment operation information exceeds any one or more of a preset vibration frequency/amplitude threshold value, a noise threshold value, a temperature threshold value and a humidity threshold value.
Optionally, the sensing module includes a vibration sensing unit, a temperature and humidity sensing unit, and a noise sensing unit;
the pre-processing module is configured to: the device is used for acquiring an idle task instruction of the sensor and controlling any one or more of the vibration sensing unit, the temperature and humidity sensing unit and the noise sensing unit to enter the sleep state according to the instruction.
Optionally, the vibration sensing unit is configured to detect X, Y and Z-axis vibration information of the target device.
In a second aspect, the present application provides an apparatus early warning device, which adopts the following technical scheme:
an equipment early warning device comprises the sensing module and the preceding processing module, wherein the preceding processing module comprises an NRF52840 chip and a communication unit connected to the NRF52840 chip, and the communication unit is used for being connected with a gateway module.
Optionally, the vibration sensing unit includes an ADXL343 vibration sensor, and a CS port of the ADXL343 vibration sensor is connected to a P0.30 interface of the NRF52840 main chip; and, its SCL is connected to SPI CLK interface of NRF52840 main chip;
the SDA is connected to the SPI MISO interface of the NRF52840 main chip;
the SDO interface is connected to the SPI MOSI interface of the NRF52840 main chip;
the interrupt pin INT1 is connected to the P0.29 interface of the NRF52840 main chip;
INT2 of the chip is connected to a P0.28 interface of an NRF52840 main chip;
its VDD and GND interfaces are connected to power and ground, respectively.
Optionally, the temperature and humidity sensing unit includes an SHT30 temperature and humidity sensor, and a data interface SDA of the SHT30 temperature and humidity sensor is connected to P1.11 of the NRF52840 main chip; and, its SCL pin is connected to P1.10 of NRF52840 main chip;
its ADDR is grounded;
the ALERT of the NRF52840 chip is connected to a P1.13 interface of the NRF52840 main chip;
its VDD and nRESER are powered up and the other interfaces are grounded.
Optionally, the noise sensing unit includes an MP34DT01 sensor, the VDD and GND of the MP34DT01 sensor are connected to power and ground, respectively, and its DOUT is connected to P0.06 of the NRF52840 main chip, its CLK is connected to P0.31 of the NRF52840 main chip, and its LR is connected to P0.26 of the NRF52840 main chip.
In summary, the present application includes at least one of the following beneficial technical effects: the method comprises the steps that a sensing module is arranged to detect vibration, temperature and humidity and noise information of equipment, and the information is sent to a server through a pre-stage processing module and a gateway module in a matched mode; the working personnel can remotely, real-timely and continuously acquire the vibration, temperature and humidity and noise information of the equipment through the interactive terminal, so that equipment faults can be discovered more timely, and labor waste is reduced; meanwhile, the preceding-stage processing module and the gateway module can also perform edge calculation, so that the AI performance of the sensor end is improved, the pressure of a server and the like is reduced, the power consumption is reduced, the maintenance is simplified, and the cost is reduced.
Drawings
FIG. 1 is a block diagram of the system of the present application;
FIG. 2 is a circuit schematic of the vibration sensing unit of the present application;
fig. 3 is a schematic circuit diagram of the temperature and humidity sensing unit of the present application;
fig. 4 is a circuit schematic diagram of a noise sensing unit of the present application.
Description of reference numerals: 1. a sensing module; 11. a vibration sensing unit; 12. a temperature and humidity sensing unit; 13. a noise sensing unit; 2. a pre-stage processing module; 3. a gateway module; 4. and (5) interacting the terminal.
Detailed Description
In order to make the objects, technical solutions and advantages of the present application more apparent, the present application is further described in detail below with reference to fig. 1-4 and the embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the present application.
The embodiment of the application discloses an equipment expected maintenance early warning system. Referring to fig. 1, the system for early warning of expected maintenance of equipment includes a sensing module 1, a pre-processing module 2, a gateway module 3, and an interactive terminal 4.
The sensing module 1 is used for detecting and outputting equipment operation information of a target unit; the device described in this embodiment takes a motor as an example, and correspondingly, the device operation information is the motor operation information. The sensing module 1 comprises a vibration sensing unit 11, a temperature and humidity sensing unit 12 and a noise sensing unit 13, and the three units are respectively used for detecting and outputting vibration information, temperature and humidity information and noise information generated when the motor runs; meanwhile, the vibration sensing unit 11 is also configured to detect X, Y of the target motor and vibration information of the Z-axis to improve the use effect.
The pre-processing module 2 comprises an integrated circuit structure using an MCU as a main chip, is connected to the output ends of the vibration sensing unit 11, the temperature and humidity sensing unit 12 and the noise sensing unit 13, and is used for receiving the operation information collected by the three units, and analyzing and processing the operation information.
The gateway module 3 is connected to the preceding-stage processing module 2, and is configured to acquire the device operation information output by the preceding-stage processing module 2, perform information interaction with a preset server, and perform information storage.
The interactive terminal 4 can select OT, CT and IT three-terminal equipment, and the interactive terminal 4 is connected to the gateway module 3 and/or the server and is used for carrying out information interaction and displaying equipment operation information through a UI (user interface); in order to improve the information display effect, the interactive terminal 4 may be configured to perform imaging processing on the device operation information, for example: and displaying through a graphical interface software Node-red.
Taking vibration information as an example: establishing a coordinate system with an X axis as time and a Y axis as frequency/amplitude, marking the three-dimensional vibration of the motor in the coordinate system, connecting coordinate points in the same dimension, and representing the three-dimensional coordinate point connection by lines in different colors. Through the imaging processing mode, the monitoring effect on the vibration of the motor can be effectively improved.
This application the system can do different settings with off-site according to on-site, on-site: the interactive terminal 4 comprises an alarm, a special mobile phone or a tablet personal computer, and performs information interaction through an IntrNet internal network; and off-site, the interactive terminal 4 comprises a mobile phone, and can communicate through a mobile/telecommunication network.
According to the content, the staff can remotely monitor the running state of the equipment such as the motor and the like through the interactive terminal 4; and because the monitoring is carried out at any time and continuously, and the information of the readable image can be known, the monitoring is more timely, even the equipment fault can be predicted in advance, and meanwhile, the system is also beneficial to reducing the labor cost.
In order to reduce the energy consumption and the service life of the system, the preceding-stage processing module 2 is further configured to acquire an idle task instruction of the sensor, and control any one or more of the vibration sensing unit 11, the temperature and humidity sensing unit 12 and the noise sensing unit 13 to enter a sleep state according to the instruction; the sensor idle task instruction can be sent to the preceding-stage processing module 2 by the interaction terminal 4 for the staff, or can be activated according to a preset sensor sleep rule in the server.
Further, any one or more of the preceding-stage processing module 2, the gateway module 3, and the server are configured to: carrying out early warning analysis processing on the equipment operation information, and outputting an alarm execution instruction if the equipment operation information meets the early warning execution condition; the alarm execution instruction comprises sending alarm information to the interactive terminal 4, controlling a plurality of specified sound/light alarms to be started and using a UI (user interface) as a popup for warning information.
The early warning processing comprises the steps of judging whether the equipment operation information exceeds any one or more of a preset vibration frequency/amplitude threshold, a noise threshold, a temperature threshold and a humidity threshold, and if so, conforming to the early warning execution condition.
If the judgment is that the gateway module 3 executes, after judging that the characteristic value is generated, the characteristic value is sent to the preceding stage processing module 2, and the characteristic value is used for improving the AI performance of the sensor end in cooperation with the preceding stage processing module 2.
The preceding stage processing module 2 and the gateway module 3 are both required for edge calculation, so that the system is low in consumption, convenient and fast to maintain, capable of reducing the requirements on servers and the like and capable of enabling the price of the system to be competitive.
In order to improve the AI capability of the sensor end, the following settings are also made in relation to the edge calculation: presetting starting conditions of a standby machine for the preceding-stage processing module 2, and outputting a standby machine starting control instruction to a predetermined standby machine by the preceding-stage processing module 2 according to the preset starting conditions of the standby machine; the preset standby machine starting condition comprises that the equipment operation information exceeds any one or more of a preset vibration frequency/amplitude threshold, a noise threshold, a temperature threshold and a humidity threshold. The threshold value is different from the early warning threshold value, and can be the same if required.
In order to facilitate the edge calculation setting, the system also collects and analyzes information in the running process of the system in a server setting database, and updates the edge calculation setting according to the analysis result; for example: after the database is analyzed, if the target equipment is damaged after the temperature is higher than 50 ℃, the logical relation is written into the sensor; the pre-processing module 2 responds accordingly when the sensor detects a temperature greater than 50 degrees celsius.
When the equipment operation information fed back by the sensing module 1 exceeds the starting condition of the standby machine, the preceding-stage processing module 2 outputs a standby machine starting control instruction to a predetermined standby machine; the standby machine is the same type of standby mechanism of the target equipment and is connected with the preceding-stage processing module 2; the arrangement can further reduce potential safety hazards caused by equipment faults and the like, and further the use effect is relatively better.
The embodiment of the application also discloses an equipment early warning device. The equipment early warning device is a preceding stage of the system and comprises the sensing module 1 and a preceding stage processing module 2.
Wherein, the pre-processing module 2 comprises an NRF52840 chip as a MCU main chip and a communication unit (such as Bluetooth 5.0+ mesh) connected with the main chip; the NRF52840 main chip is built around 32-bit ARM Cortex-M4 CPUs, and the floating point units run at 64 MHz; the method has complete multi-protocol function and complete protocol concurrency; the method has protocol support for Bluetooth 5.0, Bluetooth mesh network, thread, Zigbee, 802.15.4, ANT and 2.4 GHz proprietary stacks; it can be connected to the gateway module 3 through bluetooth, etc. to connect to the server; meanwhile, the method meets the requirements of protocol concurrency and rich and diversified peripheral equipment and functions; the communication unit is used for connecting the gateway module 3.
Referring to fig. 2, the vibration sensing unit 11 of the sensing module 1 comprises an ADXL343 vibration sensor, which is a complete 3-axis acceleration measuring system with selectable measuring ranges of ± 2 g, ± 4 g, ± 8 g or ± 16 g, with 10 to 13 bit resolution, and digital output built-in motion detection functions accessible via SPI (3 and 4 lines) and I2C to enable single click, double click, active, static and free fall, thus meeting the three-dimensional vibration detection requirements of the above-described system.
The CS port of the ADXL343 vibration sensor is connected to the P0.30 interface of the NRF52840 main chip; and, its SCL is connected to SPI CLK interface of NRF52840 main chip; the SDA is connected to the SPI MISO interface of the NRF52840 main chip; the SDO interface is connected to the SPI MOSI interface of the NRF52840 main chip; the interrupt pin INT1 is connected to the P0.29 interface of the NRF52840 main chip; INT2 of the chip is connected to a P0.28 interface of an NRF52840 main chip; its VDD and GND interfaces are connected to power and ground, respectively.
Referring to fig. 3, the temperature and humidity sensing unit 12 of the sensing module 1 includes an SHT30 temperature and humidity sensor, the SHT30 temperature and humidity sensor is built on a new CMOSens sensor chip, and the chip is the core of a Sensirion novel humidity and temperature platform; compared with the prior products, the SHT3x-DIS has higher intelligence, reliability and higher precision index.
A data interface SDA of the SHT30 temperature and humidity sensor is connected to P1.11 of the NRF52840 main chip; and, its SCL pin is connected to P1.10 of NRF52840 main chip; its ADDR is grounded; the ALERT of the NRF52840 chip is connected to a P1.13 interface of the NRF52840 main chip; its VDD and nRESER are powered up and the other interfaces are grounded.
Referring to fig. 4, the noise sensing unit 13 of the sensing module 1 includes an MP34DT01 sensor, the MP34DT01 sensor is a subminiature 3mm 4mm 1mm, low power consumption, full-scale digital MEMS microphone with a built-in capacitive sensing element and IC interface, and the sensing element capable of detecting sound waves is manufactured using a dedicated silicon micromachining process specially used for manufacturing audio sensors.
The VDD and GND of the MP34DT01 sensor are connected to power and ground, respectively, and its DOUT is connected to P0.06 of NRF52840 main chip, its CLK is connected to P0.31 of NRF52840 main chip, and its LR is connected to P0.26 of NRF52840 main chip.
The foregoing is a preferred embodiment of the present application and is not intended to limit the scope of the application in any way, and any features disclosed in this specification (including the abstract and drawings) may be replaced by alternative features serving equivalent or similar purposes, unless expressly stated otherwise. That is, unless expressly stated otherwise, each feature is only an example of a generic series of equivalent or similar features.
Claims (10)
1. An equipment intended maintenance early warning system, comprising:
a sensing module (1) configured to: the device operation information used for detecting the target unit is output; the equipment operation information comprises vibration information, temperature and humidity information and noise information;
a pre-processing module (2) connected to the sensing module (1) and configured to: the device is used for analyzing and processing the equipment operation information and outputting the equipment operation information;
a gateway module (3) connected to the pre-processing module (2) and configured to: the device operation information acquisition module is used for acquiring the device operation information output by the preceding-stage processing module (2), and performing information interaction, analysis processing and information storage with a preset server; and the number of the first and second groups,
an interaction terminal (4) connected to the gateway module (3) and/or server and configured to: the information interaction device is used for carrying out information interaction and displaying the running information of the equipment through the UI interface.
2. The system of claim 1, wherein: any one or more of the pre-processing module (2), the gateway module (3) and the server are configured to: and carrying out early warning analysis processing on the equipment operation information, and outputting an alarm execution instruction if the equipment operation information meets the early warning execution condition.
3. The system of claim 2, wherein: the early warning analysis processing comprises the step of judging whether the equipment operation information exceeds any one or more of a preset vibration frequency/amplitude threshold, a noise threshold, a temperature threshold and a humidity threshold.
4. The system of claim 2, wherein: the pre-processing module (2) is further configured to: outputting a standby machine starting control instruction to a preset standby machine according to a preset standby machine starting condition; wherein, the standby machine starting condition comprises that the equipment operation information exceeds any one or more of a preset vibration frequency/amplitude threshold value, a noise threshold value, a temperature threshold value and a humidity threshold value.
5. The system of claim 1, wherein: the sensing module (1) comprises a vibration sensing unit (11), a temperature and humidity sensing unit (12) and a noise sensing unit (13);
the pre-processing module (2) is configured to: the device is used for acquiring an idle task instruction of the sensor and controlling any one or more of the vibration sensing unit (11), the temperature and humidity sensing unit (12) and the noise sensing unit (13) to enter the sleep state according to the instruction.
6. The system of claim 5, wherein: the vibration sensing unit (11) is used for detecting X, Y and Z-axis vibration information of the target device.
7. An equipment early warning device, its characterized in that: comprising a sensing module (1) according to any of claims 1 to 6 and a pre-processing module (2), the pre-processing module (2) comprising an NRF52840 chip and a communication unit connected to the NRF52840 chip, the communication unit being adapted to be connected to a gateway module.
8. The equipment warning device according to claim 7, wherein: the vibration sensing unit (11) comprises an ADXL343 vibration sensor, and a CS port of the ADXL343 vibration sensor is connected to a P0.30 interface of an NRF52840 main chip; and, its SCL is connected to SPI CLK interface of NRF52840 main chip;
the SDA is connected to the SPI MISO interface of the NRF52840 main chip;
the SDO interface is connected to the SPI MOSI interface of the NRF52840 main chip;
the interrupt pin INT1 is connected to the P0.29 interface of the NRF52840 main chip;
INT2 of the chip is connected to a P0.28 interface of an NRF52840 main chip;
its VDD and GND interfaces are connected to power and ground, respectively.
9. The equipment warning device according to claim 7, wherein: the temperature and humidity sensing unit (12) comprises an SHT30 temperature and humidity sensor, and a data interface SDA of the SHT30 temperature and humidity sensor is connected to P1.11 of the NRF52840 main chip; and, its SCL pin is connected to P1.10 of NRF52840 main chip;
its ADDR is grounded;
the ALERT of the NRF52840 chip is connected to a P1.13 interface of the NRF52840 main chip;
its VDD and nRESER are powered up and the other interfaces are grounded.
10. The equipment warning device according to claim 7, wherein: the noise sensing unit (13) comprises an MP34DT01 sensor, the VDD and GND of the MP34DT01 sensor are respectively connected with a power supply and a ground, the DOUT thereof is connected to the P0.06 of the NRF52840 main chip, the CLK thereof is connected to the P0.31 of the NRF52840 main chip, and the LR thereof is connected to the P0.26 of the NRF52840 main chip.
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| CN202110133790.0A CN112967478A (en) | 2021-02-01 | 2021-02-01 | Equipment expected maintenance early warning system and early warning device thereof |
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