CN113280910A - Real-time monitoring method and system for long product production line equipment - Google Patents
Real-time monitoring method and system for long product production line equipment Download PDFInfo
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Abstract
The invention provides a real-time monitoring method and a real-time monitoring system for long product production line equipment, wherein the method comprises the following steps: acquiring a vibration monitoring value of target equipment in real time; converting the vibration monitoring value into an equipment running state map by using a preset data analysis module and outputting the map in real time; and diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard, and outputting the equipment running state which is obtained by diagnosis and corresponds to the vibration monitoring value. The invention can monitor production line equipment in real time, is beneficial to helping production enterprises to carry out preventive maintenance on the production equipment, thereby improving the safe operation period of the equipment, saving the maintenance cost and avoiding sudden faults and accidents.
Description
Technical Field
The invention relates to the technical field of equipment monitoring, in particular to a real-time monitoring method and system for long product production line equipment.
Background
Whether the unit equipment of the high-speed wire rod production line operates normally or not is directly related to the production of enterprises, and as the ferrous metallurgy industry belongs to the continuous process industry, the influence of key equipment faults on the production is particularly great. In the actual working process, due to the long-time continuous operation, the severe operating condition, the low redundancy of the equipment load design, the poor lubrication reliability of the rotating parts, the manufacturing and installation and other reasons, the common faults of various rotating machines often occur to the unit equipment, and the serious consequences are brought to the normal safe production of enterprises.
In the prior art, no related system can monitor the equipment condition in real time, enterprises cannot make a predictive maintenance plan in advance, and the enterprises can usually deal with the situation when the production line is blocked due to serious faults of the equipment, so that the enterprises are quite passive in the production operation process, and even the enterprises can bring huge loss.
Disclosure of Invention
The invention aims to provide a real-time monitoring method and a real-time monitoring system for equipment in a long material production line, which are used for solving the technical problems, can monitor the production line equipment in real time and are beneficial to helping production enterprises to perform preventive maintenance, so that the safe operation period of the equipment can be prolonged, the maintenance cost can be saved, and sudden faults and accidents can be avoided.
In order to solve the technical problem, the invention provides a real-time monitoring method for long product production line equipment, which comprises the following steps:
acquiring a vibration monitoring value of target equipment in real time;
converting the vibration monitoring value into an equipment running state map by using a preset data analysis module and outputting the map in real time;
and diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard, and outputting the equipment running state which is obtained by diagnosis and corresponds to the vibration monitoring value.
Further, the diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard, and outputting the device operation state obtained by diagnosis and corresponding to the vibration monitoring value specifically includes:
diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard;
when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment to be a normal running state;
when the vibration monitoring value of the target equipment is judged to be within a preset second threshold value range, outputting the equipment running state of the target equipment to be a slight fault state;
and when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment as a serious fault state.
Further, the real-time monitoring method for the long product production line equipment further comprises the following steps:
and when the target equipment is judged to be in a fault state, extracting vibration frequency characteristics from the equipment running state map, and identifying a fault source of the target equipment according to the vibration frequency characteristics.
Further, the real-time monitoring method for the long product production line equipment further comprises the following steps:
and when the target equipment is judged to be in a fault state, extracting vibration frequency characteristics from the equipment operation state map, and identifying the fault development degree of the target equipment according to the vibration frequency characteristics.
Further, the vibration monitoring value of the target equipment comprises one or more of a motor vibration monitoring value, a speed increasing box vibration monitoring value, a cone box vibration monitoring value and a laying head vibration monitoring value.
In order to solve the same technical problem, the invention also provides a real-time monitoring system for long product production line equipment, which comprises:
the data acquisition module is used for acquiring a vibration monitoring value of the target equipment in real time;
the data analysis module is used for converting the vibration monitoring value into an equipment running state map by using a preset data analysis module and outputting the map in real time;
and the fault diagnosis module is used for diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard and outputting the equipment running state which is obtained by diagnosis and corresponds to the vibration monitoring value.
Further, the root fault diagnosis module is specifically configured to: diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard; when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment to be a normal running state; when the vibration monitoring value of the target equipment is judged to be within a preset second threshold value range, outputting the equipment running state of the target equipment to be a slight fault state; and when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment as a serious fault state.
Further, the real-time monitoring system for the long product production line equipment further comprises a fault source identification module, wherein the fault source identification module is used for extracting vibration frequency characteristics from the equipment running state spectrum when the target equipment is judged to be in a fault state, and identifying a fault source of the target equipment according to the vibration frequency characteristics.
Further, the real-time monitoring system for the long product production line equipment further comprises a fault degree identification module, wherein the fault degree identification module is used for extracting vibration frequency characteristics from the equipment running state map and identifying the fault development degree of the target equipment according to the vibration frequency characteristics when the target equipment is judged to be in a fault state.
Further, the vibration monitoring value of the target equipment comprises one or more of a motor vibration monitoring value, a speed increasing box vibration monitoring value, a cone box vibration monitoring value and a laying head vibration monitoring value.
Compared with the prior art, the invention has the following beneficial effects:
the invention provides a real-time monitoring method and a real-time monitoring system for long product production line equipment, wherein the method comprises the following steps: acquiring a vibration monitoring value of target equipment in real time; converting the vibration monitoring value into an equipment running state map by using a preset data analysis module and outputting the map in real time; and diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard, and outputting the equipment running state which is obtained by diagnosis and corresponds to the vibration monitoring value. The invention can monitor production line equipment in real time, is beneficial to helping production enterprises to carry out preventive maintenance on the production equipment, thereby improving the safe operation period of the equipment, saving the maintenance cost and avoiding sudden faults and accidents.
Drawings
Fig. 1 is a schematic flow chart of a real-time monitoring method for long product production line equipment according to an embodiment of the present invention;
fig. 2 is a schematic structural diagram of a real-time monitoring system for long product production line equipment according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, an embodiment of the present invention provides a real-time monitoring method for long product production line equipment, including the steps of:
and S1, acquiring the vibration monitoring value of the target equipment in real time. The vibration monitoring value of the target equipment comprises one or more of a motor vibration monitoring value, a speed increasing box vibration monitoring value, a cone box vibration monitoring value and a laying head vibration monitoring value.
And S2, converting the vibration monitoring value into an equipment running state map by using a preset data analysis module and outputting the map in real time.
And S3, diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard, and outputting the equipment running state obtained by diagnosis and corresponding to the vibration monitoring value.
In the embodiment of the present invention, further, step S3 specifically includes:
diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard;
when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment to be a normal running state;
when the vibration monitoring value of the target equipment is judged to be within a preset second threshold value range, outputting the equipment running state of the target equipment to be a slight fault state;
and when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment as a serious fault state.
In an embodiment of the present invention, further, the real-time monitoring method for long product production line equipment further includes:
and S4, when the target equipment is judged to be in the fault state, extracting vibration frequency characteristics from the equipment running state map, and identifying the fault source of the target equipment according to the vibration frequency characteristics.
In an embodiment of the present invention, further, the real-time monitoring method for long product production line equipment further includes:
and S5, when the target equipment is judged to be in the fault state, extracting vibration frequency characteristics from the equipment operation state map, and identifying the fault development degree of the target equipment according to the vibration frequency characteristics.
Based on the above scheme, in order to better understand the real-time monitoring method for the long product production line equipment provided by the embodiment of the invention, the following detailed description is provided:
1. overall objective: the implementation object of the embodiment of the invention is mainly to carry out online monitoring on a high-speed wire rod production line finishing mill and a wire laying head. The method mainly comprises the following steps:
(1) online monitoring: and establishing an online monitoring system covering key parts and key fault forms of the implementation object. And collecting complete equipment operation data and establishing an operation file. The vibration monitoring and fault diagnosis technology is comprehensively applied, the running state of the equipment is known in time, and the degradation trend of the running period is mastered.
(2) Fault diagnosis: the fault data are analyzed in detail, and the fault position, damage form and severity of the equipment are diagnosed through various signal processing means such as spectrum analysis, measurement point trend graph analysis, correlation analysis and the like.
(3) Digital twinning: the field equipment is modeled by 3D, and the field real-time data is displayed in the operation and maintenance monitoring center in time by means of digital twinning, so that the fault degradation trend is found in time, the shutdown and the first-aid repair are realized in time, and the normal operation of the whole line is ensured.
The embodiment of the invention provides favorable data support for the work of equipment maintenance, operation guarantee, maintenance plan and the like through the implementation of the online monitoring project. The safe operation period of the equipment is prolonged, the maintenance cost is saved, and sudden faults and accidents are avoided.
2. Scheme of on-line monitoring system
(1) Monitoring an object
The monitoring objects of the embodiment of the invention comprise a finishing mill and a laying head. Both of these units are direct and critical production equipment on high-speed wire production lines, and are also typical equipment. The monitoring of the two groups of equipment not only has direct effect on equipment guarantee, but also has wide demonstration and popularization effects.
(2) Monitoring method
Vibration can be exacerbated when the drive train is not operating properly or when a component fails. Measuring the amount of vibration is therefore the most effective means for condition monitoring and fault diagnosis of rotating mechanical systems. Therefore, the embodiment of the invention adopts the technical means of vibration monitoring to comprehensively monitor the transmission systems of the finishing mill and the laying head.
Finishing mills and laying heads belong to key equipment, and the working conditions are extremely complex. The following measures are taken to ensure an effective measurement of the vibrations: 1) a sensor with good pass-frequency performance and stability is used, so that low-frequency signals can be acquired; 2) the data acquisition unit ensures that the low-frequency signals are converted into digital signals without attenuation, and accurate records are obtained; 3) the acquisition length of data is prolonged, so that the vibration signal comprises more cycles, and the signal analysis result is more stable and reliable; 4) and demodulating a tiny impact signal of the bearing and the gear from the high-frequency signal by using an analysis method such as resonance demodulation, and diagnosing the faults of the bearing and the gear.
(3) Data acquisition
According to the data acquisition method and device, an SMH Pioneer I channel network data acquisition instrument is used for data acquisition, and 16 paths of vibration signals are measured simultaneously. Aiming at high-speed rotating equipment such as a finishing mill cone box, a laying head and the like, the SMH Pioneer I can acquire the rotating speed of a motor while acquiring a vibration signal, so that the rotating speed tracking is realized.
The SMH Pioneer I communicates with the database server through a wired Ethernet network and uploads the data to an online monitoring system on the server.
An industrial personal computer is arranged in the main control room and used as a database server, and the industrial personal computer is accessed to an enterprise local area network or an external network.
(4) Device status and fault diagnostics
The SMH on-line monitoring system running on the monitoring host provides a plurality of signal analysis means, analyzes the on-line monitoring data, and identifies whether each device has an abnormal state, and the parts, the fault forms and the severity of the faults.
The online monitoring system collects vibration values of all measuring points of the equipment and judges the running state of the equipment according to the vibration threshold value. The limit value of the vibration amount is determined according to the allowable value of the dynamic load and vibration which the bearings and gears are allowed to bear, and the allowable value of the vibration transmitted to the surrounding environment through the supporting structure and the foundation, and the maximum vibration amount value measured on each bearing or base is evaluated against an evaluation area (vibration value threshold range) established by experience. Different vibration region boundary values (higher or lower) can be used for different models of equipment according to special performance requirements, but the equipment is guaranteed not to be damaged under high vibration values (the vibration intensity region boundary values only provide equipment operation state references and are not used as acceptance specifications).
One standard vibration intensity zone division is listed below:
and (3) area A: the equipment vibration of the newly delivered use usually belongs to the area;
and a region B: it is generally accepted that equipment with vibration values in this region can operate for unlimited long periods of time;
and (3) area C: the equipment is not suitable for long-term continuous operation due to internal failure;
and (3) area D: the vibration is strong, the fault is serious enough to cause the damage of the equipment;
the monitoring host is accessed to the enterprise local area network, and all computers on the same local area network can check the equipment condition to perform fault analysis.
3. Vibration monitoring method
3.1 finishing mill cone box
The finishing mill cone box transmission system is powered by a variable-frequency speed-regulating main motor, after the speed is increased by a speed increasing box, the cone boxes on two sides are driven to rotate by a gear pair, and the cone boxes on the same side are connected through a coupler. The finishing mill cone box transmission system is the key point of monitoring and comprises a motor, a speed increasing box and cone boxes of all frames.
Mechanical component failures that may occur in these systems include:
(1) a motor: the internal stator and the rotor are unbalanced, and different shafts or bearings are damaged; shaft bending, etc.
(2) Coupling: poor centering.
(3) A speed increasing box: gear engagement, pitting due to bearing wear, fatigue peeling, wear, poor lubrication, and the like.
(4) A cone box: gear engagement, pitting due to bearing wear, fatigue peeling, wear, poor lubrication, and the like.
In the embodiment of the invention, in order to comprehensively monitor and identify the faults, the monitoring positions are determined as follows:
(1) the free end of the motor: and measuring the radial vibration of the bearing seat. And monitoring faults of a rotor, a stator and a bearing in the motor.
(2) A motor load end: and measuring the radial vibration of the bearing seat. And monitoring faults of a rotor, a stator and a bearing in the motor and a coupling centering state.
(3) Input end of 1# shaft of speed increasing box: the bearing seat radial and axial vibrations are measured. Monitoring the 1# shaft bearing fault and the coupling centering state.
(4) Output end of speed increasing box 2# shaft: and measuring the radial vibration of the bearing seat. And monitoring faults of the gear and the bearing and a coupling centering state.
(5) Output end of speed increasing box 3# shaft: and measuring the radial vibration of the bearing seat. And monitoring faults of the gear and the bearing and a coupling centering state.
(6) A cone box: and measuring the radial and axial vibration of the longitudinal axis cone axis. And monitoring the alignment state of the longitudinal shaft, the conical shaft bearing, the gear and the coupling.
The finishing mill cone box transmission system monitors 46 measuring points in total, and comprises 2 motors, 4 speed increasing boxes and 4 cone boxes per platform (10 machine frame cone boxes). A total of 46 vibration sensors are required.
In the embodiment of the invention, each acquisition station (SMH Pioneer I) can acquire 16 channels, and 46 sensors arranged in a finishing mill cone box transmission system need 3 SMH Pioneer I to acquire data.
3.2 laying head
The driving system of the laying head is a gear pair of the laying head directly driven by a main motor. The monitoring object comprises a motor and a laying head.
Common faults of laying heads are: unbalance, misalignment, bearing damage, poor gear engagement and the like; to fully monitor the operating state of the laying head, the monitoring positions are determined as follows:
(1) the free end of the motor: and measuring the radial vibration of the bearing seat. And monitoring faults of a rotor, a stator and a bearing in the motor.
(2) A motor load end: and measuring the radial vibration of the bearing seat. And monitoring faults of a rotor, a stator and a bearing in the motor and a coupling centering state.
(3) Laying head drive shaft: the bearing seat radial and axial vibrations are measured. Drive shaft bearing failure, and coupling centering conditions are monitored.
(4) Hollow shaft of laying head: the bearing seat radial and axial vibrations are measured. And monitoring faults of the gear and the bearing and a coupling centering state.
The estimated 10 measuring points of the transmission system of the laying head are monitored, and comprise 2 motors, 8 laying heads, 10 vibration sensors and 1 acquisition station (SMH Pioneer I).
4. Online monitoring system hardware description
4.1 on-line monitoring acquisition station
The on-line monitoring acquisition station is an on-line state detection module specially designed for rotating machinery. It can collect 16 sensor signals and 2 speed signals and realize synchronous trigger collection of speed. The test data is transmitted to the monitoring computer by the wired Ethernet mode to be displayed and stored in real time.
The product structure of the on-line monitoring acquisition station conforms to the IP65 protection standard and can be installed on industrial sites with severe environment. Typical applications include monitoring of various different types of motors, fans, pumps, gearboxes, mills, wind generators, power stations and centrifuges, and general vibration, imbalance, misalignment, fatigue and bearing conditions of various mechanical equipment. The on-line monitoring acquisition station can simultaneously acquire data of 16 vibration channels and data of 2 rotating speed channels.
4.2 vibration sensor
Pass frequency vibration acceleration sensor
The military connector is waterproof and dustproof, is simple and convenient to mount, has strong anti-interference performance and is convenient to maintain, and can be used in industrial fields with severe environments. The main technical parameters are as follows:
1) sensitivity: 100mV/g
2) Measurement range: 80g of
3) Frequency range (± 3 dB): (0.4-15K) Hz
4) Temperature range: -54 ℃ to 121 DEG C
4.3, speed sensor
1) Power supply voltage: DC 10V-30V
2) The rotating speed range is as follows: 700Hz
3) Working clearance: less than or equal to 5mm
4) The applicable materials are as follows: magnetic steel is pasted on the rotating shaft, and S pole is aligned with the rotating speed sensor
5) Working temperature: -20 ℃ to 80 DEG C
6) The external dimension is as follows: M12X 1 external thread
4.4 Online monitoring software System
An SMH online monitoring system (SMH for short) software runs on a monitoring host. And a plurality of SMH Pioneer I online monitoring and collecting stations are connected through a wired network to carry out data collection, fault analysis and data management. The method has the functions of trend analysis, time domain waveform, spectrum analysis, waveform reprocessing, waterfall diagram, multi-time domain/multi-frequency domain analysis, envelope demodulation, cepstrum analysis and the like. Through data analysis, the purposes of identifying fault sources and determining fault degrees are achieved.
The equipment state: and checking the state of each measuring point on the equipment, and if the vibration intensity exceeds the early warning value, marking the state with different colors.
And (3) data analysis: the on-line monitoring system has a data processing function, original vibration waveforms are processed into an amplitude spectrogram, and specific frequency or frequency band waveforms can be filtered out through functions of reprocessing, envelope demodulation, cepstrum and the like;
the source of the failure: under a certain operation state of the equipment, various fault types (such as unbalanced fault, bearing fault, gear meshing failure, oil film whirl and the like) correspond to specific vibration frequency, and the fault source of the equipment can be determined in a vibration spectrogram;
degree of failure: different fault sources have typical maps of the initial fault, the middle fault and the later fault, and the fault development degree can be judged by comparing the typical maps with the vibration map of the equipment.
4.5 data analysis function
The data analysis module comprises: the method has the functions of trend analysis, time domain waveform, spectrum analysis, waveform reprocessing, waterfall diagram, multi-time domain/multi-frequency domain analysis, envelope demodulation, cepstrum analysis and the like.
(1) Trend analysis
(2) Time domain waveform
The vibration waveform can be viewed by selecting analysis measuring points, time ranges and rotating speed.
(3) Spectral analysis
The spectrum analysis is an important tool for fault vibration analysis, and the SMH spectrum analysis also comprises tools such as harmonic waves, edge frequency cursors and the like, so that the relation between peak frequencies can be checked more conveniently.
(4) Waveform reprocessing
The wave form is added with the filtering modes of band-pass, band-stop, high-pass and low-pass, the passing frequency can be freely set, and a certain section of frequency is intercepted for detailed analysis.
(5) Waterfall chart
The waterfall plot can analyze the change rule of the frequency spectrum in the signal within a period of time to know the evolution condition of the fault. The SMH can select the analysis stations and time ranges to view the waveform spectrum.
(6) Multi-time domain/multi-frequency domain analysis
The SMH online monitoring system can display the time domain waveform and the frequency spectrum waveform in the selected time in a set mode, so that comparison and analysis are facilitated, and a fault source of equipment is determined.
(7) Envelope demodulation
Envelope demodulation can modulate the vibration signal who gathers, filters out more clutter noise signal, remains the signal that vibration analysis needs, is used for judging bearing early failure.
(8) Cepstrum analysis
Cepstral analysis is also known as cepstrum, quadratic spectrum, log power spectrum; the method is used for extracting and analyzing periodic signals which are difficult to identify by naked eyes on the original spectrogram, and can simplify the side band spectral lines of a family on the original spectrogram into a single spectral line; the method is often used for judging the fault of the rolling bearing retainer.
(9) Cross phase
The SMH on-line monitoring system judges the running state of the rotor by comparing the vibration phases of different measuring point positions at the same time, visually displays the fault characteristics of the rotating equipment and is convenient for finding the fault source.
It should be noted that all the maps in the state display and analysis in the SMH can generate reports in Excel format, so as to form a paper running archive of the device state conveniently. In addition, reports such as alarm records, system logs and the like can be generated.
4.6 Intelligent Algorithm
(1) Baseline model
And acquiring long-term operation data of the equipment to form a baseline. Then, the following conditions are pre-warned:
1) and judging whether the poor operation state exists or not from the change trend of the baseline. The steep trend can be caused by improper manual operation or overload running;
2) setting a multi-level alarm threshold according to a base line under normal operation, and alarming in a corresponding type when the acquired data exceeds the corresponding threshold;
(2) RUL model
1. In the absence of the feature "residual life", the model is established by:
1) and carrying out Fourier transform on the acquired time domain waveform to obtain a frequency spectrum waveform.
2) And calculating the characteristic frequency of each part according to the unique drawing data.
3) And (4) performing trend fitting on the characteristic frequency of each part, and predicting the time for reaching a given threshold value, namely the residual life. And the given threshold value can be a national standard value or an expert experience value.
2. After sufficient residual life data are acquired through data accumulation, the residual life can be used as a target value to carry out traditional machine learning or deep learning.
1) Conventional machine learning. And extracting features of the map data, such as peak value, peak-to-peak value, peak coefficient, margin, kurtosis and the like. Respectively building a traditional machine learning model for each type of parts, wherein the traditional machine learning model comprises Xgboost, Ridge regression, Lasso regression, ElasticNet regression, GBDT, LGBM and the like;
2) and (4) deep learning. The multi-frequency spectrum is converted into a binary image by audio-like STFT transformation, where the length and width of the image represent time and frequency, respectively, and the shade of the image represents the amplitude of the frequency at a given time. And finally training to obtain the residual life of the part through a multilayer neural network.
4.7 digital twinning
And the digital twin enables the equipment of the on-site production line to be modeled in a comprehensive 3D mode, and the unified real-time mechanical operation condition display and monitoring are carried out on the operation and maintenance platform. The SMH online operation and maintenance platform can display the operation condition of the field equipment in real time, and through an SMH Pioneer I acquisition system deployed in a production field, the real-time operation edge parameters of the field equipment are in instant communication with the SMH through a safety protocol, so that the vibration, the rotating speed, the temperature and the oil of the equipment are displayed in real time, and the equipment deterioration trend is fed back in time.
1. 3D modeling field equipment and all spare parts are adopted;
2. displaying the operating parameters of the field equipment in real time in the established model;
3. and alarming equipment failure and degradation trend in real time.
It should be noted that the above method or flow embodiment is described as a series of acts or combinations for simplicity, but those skilled in the art should understand that the present invention is not limited by the described acts or sequences, as some steps may be performed in other sequences or simultaneously according to the present invention. Further, those skilled in the art will appreciate that the embodiments described in the specification are exemplary embodiments and that no single embodiment is necessarily required by the inventive embodiments.
Referring to fig. 2, in order to solve the same technical problem, the present invention further provides a real-time monitoring system for long product production line equipment, comprising:
the data acquisition module 1 is used for acquiring a vibration monitoring value of target equipment in real time;
the data analysis module 2 is used for converting the vibration monitoring value into an equipment running state map by using a preset data analysis module and outputting the map in real time;
and the fault diagnosis module 3 is used for diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard and outputting the equipment running state which is obtained by diagnosis and corresponds to the vibration monitoring value.
In the embodiment of the present invention, further, the root fault diagnosis module 3 is specifically configured to: diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard; when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment to be a normal running state; when the vibration monitoring value of the target equipment is judged to be within a preset second threshold value range, outputting the equipment running state of the target equipment to be a slight fault state; and when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment as a serious fault state.
In the embodiment of the present invention, the real-time monitoring system for long product production line equipment further includes a fault source identification module, configured to extract a vibration frequency feature from the equipment operation state map when it is determined that the target equipment is in a fault state, and identify a fault source of the target equipment according to the vibration frequency feature.
In the embodiment of the present invention, the real-time monitoring system for long product production line equipment further includes a fault degree identification module, configured to extract a vibration frequency feature from the equipment operation state map when it is determined that the target equipment is in a fault state, and identify a fault development degree of the target equipment according to the vibration frequency feature.
In the embodiment of the present invention, further, the vibration monitoring value of the target device includes one or more of a motor vibration monitoring value, a speed increasing box vibration monitoring value, a conical box vibration monitoring value, and a laying head vibration monitoring value.
It can be understood that the above system embodiment corresponds to the method embodiment of the present invention, and the real-time monitoring system for long product production line equipment provided in the embodiment of the present invention can implement the real-time monitoring method for long product production line equipment provided in any method embodiment of the present invention.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.
Claims (10)
1. A real-time monitoring method for long product production line equipment is characterized by comprising the following steps:
acquiring a vibration monitoring value of target equipment in real time;
converting the vibration monitoring value into an equipment running state map by using a preset data analysis module and outputting the map in real time;
and diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard, and outputting the equipment running state which is obtained by diagnosis and corresponds to the vibration monitoring value.
2. The real-time monitoring method for the long product production line equipment according to claim 1, wherein the real-time diagnosis is performed on the vibration monitoring value according to a preset fault diagnosis standard, and the equipment operation state obtained through diagnosis and corresponding to the vibration monitoring value is output, and specifically comprises:
diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard;
when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment to be a normal running state;
when the vibration monitoring value of the target equipment is judged to be within a preset second threshold value range, outputting the equipment running state of the target equipment to be a slight fault state;
and when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment as a serious fault state.
3. The real-time monitoring method for the long product production line equipment as claimed in claim 1, further comprising:
and when the target equipment is judged to be in a fault state, extracting vibration frequency characteristics from the equipment running state map, and identifying a fault source of the target equipment according to the vibration frequency characteristics.
4. The real-time monitoring method for the long product production line equipment as claimed in claim 1, further comprising:
and when the target equipment is judged to be in a fault state, extracting vibration frequency characteristics from the equipment operation state map, and identifying the fault development degree of the target equipment according to the vibration frequency characteristics.
5. The real-time monitoring method for the long product production line equipment as claimed in claim 1, wherein the vibration monitoring value of the target equipment comprises one or more of a motor vibration monitoring value, a speed increasing box vibration monitoring value, a cone box vibration monitoring value and a laying head vibration monitoring value.
6. The utility model provides a long material production line equipment real-time monitoring system which characterized in that includes:
the data acquisition module is used for acquiring a vibration monitoring value of the target equipment in real time;
the data analysis module is used for converting the vibration monitoring value into an equipment running state map by using a preset data analysis module and outputting the map in real time;
and the fault diagnosis module is used for diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard and outputting the equipment running state which is obtained by diagnosis and corresponds to the vibration monitoring value.
7. The real-time monitoring system for long product production line equipment according to claim 6, wherein the root fault diagnosis module is specifically configured to: diagnosing the vibration monitoring value in real time according to a preset fault diagnosis standard; when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment to be a normal running state; when the vibration monitoring value of the target equipment is judged to be within a preset second threshold value range, outputting the equipment running state of the target equipment to be a slight fault state; and when the vibration monitoring value of the target equipment is judged to be within a preset first threshold value range, outputting the equipment running state of the target equipment as a serious fault state.
8. The real-time monitoring system of long product production line equipment as claimed in claim 6, further comprising a fault source identification module for extracting vibration frequency characteristics from the equipment operation state map and identifying a fault source of the target equipment according to the vibration frequency characteristics when the target equipment is determined to be in a fault state.
9. The real-time monitoring system of long product production line equipment as claimed in claim 6, further comprising a fault degree identification module for extracting vibration frequency characteristics from the equipment operation state map and identifying the fault development degree of the target equipment according to the vibration frequency characteristics when the target equipment is determined to be in the fault state.
10. The real-time monitoring system for long product production line equipment as claimed in claim 6, wherein the vibration monitoring value of the target equipment comprises one or more of a motor vibration monitoring value, a speed increasing box vibration monitoring value, a cone box vibration monitoring value and a laying head vibration monitoring value.
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