CN113405824A - Fault prediction system and method for variable-speed variable-load intermittent operation equipment - Google Patents
Fault prediction system and method for variable-speed variable-load intermittent operation equipment Download PDFInfo
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- CN113405824A CN113405824A CN202110536655.0A CN202110536655A CN113405824A CN 113405824 A CN113405824 A CN 113405824A CN 202110536655 A CN202110536655 A CN 202110536655A CN 113405824 A CN113405824 A CN 113405824A
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- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
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- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
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- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
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Abstract
The invention provides a fault prediction system and a method for variable-speed variable-load intermittent operation equipment, which comprises the following steps: collecting ultrasonic signals generated by the running of a rotating part in variable-speed variable-load intermittent running equipment by using a detection sensor; the detection sensor is arranged on the variable-speed variable-load intermittent operation equipment and is in contact with the variable-speed variable-load intermittent operation equipment; collecting the ultrasonic signals collected by the detection sensor through a data collecting and processing device, and transmitting the ultrasonic signals after the collection processing to a remote monitoring server; and storing the collected ultrasonic signals through a remote monitoring server, and predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the stored ultrasonic signals. The invention arranges the fault prediction system on the variable speed and variable load intermittent operation equipment, and can realize the display of the health/alarm state of the variable speed and variable load intermittent operation equipment on a terminal computer and a personal mobile phone terminal by an intelligent early warning method.
Description
Technical Field
The invention relates to the technical field of equipment detection, in particular to a fault prediction system and method for variable-speed variable-load intermittent operation equipment.
Background
At present, variable-speed variable-load intermittent operation equipment is widely applied in the process industry, such as a large number of rolling mills, crown blocks (bridge cranes), shearing machines (cold shears and flying shears) in the metallurgical industry, mills and rolling presses in the building material industry, and the like. At present, the difficulty of monitoring variable-speed, variable-load and intermittent equipment is high, the traditional monitoring means such as temperature, vibration, current and the like are greatly influenced by working conditions, and the mechanical fault and/or the electrical fault of the equipment are difficult to accurately warn, so that the equipment is often repaired after the equipment breaks down. In addition, at present, the state monitoring of the equipment mostly depends on equipment management personnel to carry out periodic point inspection, and then the equipment is periodically maintained based on a point inspection result, but the application of continuously monitoring the state of the equipment on line is less, and meanwhile, the working environment of the equipment is severe and the requirement on a monitoring system is higher.
Disclosure of Invention
In view of the above drawbacks of the prior art, an object of the present invention is to provide a system and a method for predicting a failure of a variable speed and variable load intermittent operation device, which are used to solve the problem of difficulty in monitoring and early warning of the variable speed and variable load intermittent operation device in the prior art.
To achieve the above and other related objects, the present invention provides a failure prediction system for a variable speed variable load intermittent operation apparatus, comprising:
the detection sensor is used for acquiring ultrasonic signals generated when a rotating component in the variable-speed variable-load intermittent operation equipment runs; the detection sensor is arranged on the variable-speed variable-load intermittent operation equipment and is in contact with the variable-speed variable-load intermittent operation equipment;
the data collecting and processing device is used for collecting and processing the ultrasonic signals collected by the detection sensor and transmitting the collected and processed ultrasonic signals to the remote monitoring server;
and the remote monitoring server is used for storing the collected ultrasonic signals and predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the stored ultrasonic signals.
Optionally, the system further comprises an OPC communication module, which is disposed in the remote monitoring server and is configured to transmit the production process data of the variable speed variable load intermittent operation device to the remote monitoring server;
the remote monitoring server comprises a database and an intelligent analysis module;
the database is used for storing the collected ultrasonic signals, storing production process data of the variable-speed variable-load intermittent operation equipment and taking the stored ultrasonic signals as state data of the variable-speed variable-load intermittent operation equipment;
the intelligent analysis module is used for predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment.
Optionally, the system further comprises an early warning device, wherein the early warning device is connected with the intelligent analysis module and used for sending out an early warning signal according to a prediction result of the intelligent analysis module; wherein the early warning signal comprises: acoustic signals, optical signals, text messages, and/or WeChat popup windows.
Optionally, the process of predicting whether the variable-speed variable-load intermittent operation equipment has a fault by the intelligent analysis module according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment comprises:
judging the circuit state of the detection sensor, wherein the circuit state comprises the following steps: open, short and open;
when the detection sensors are positioned in a passage state, acquiring ultrasonic signal values of the variable-speed variable-load intermittent operation equipment detected by all the detection sensors at the current moment from a database;
comparing the ultrasonic signal values detected by all the detection sensors at the current moment with a first comparison threshold value and/or a second comparison threshold value preset in the intelligent analysis module;
if the ultrasonic signal values detected by all the detection sensors at the current moment are smaller than a first comparison threshold value, judging that the variable-speed variable-load intermittent operation equipment is in a healthy state, and predicting that no fault exists in the variable-speed variable-load intermittent operation equipment;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a first comparison threshold value and smaller than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a primary alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a serious alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal values detected by all the detection sensors at the current moment are larger than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in an emergency fault alarm state, and the fault of the variable-speed variable-load intermittent operation equipment is predicted;
the first comparison threshold and the second comparison threshold are generated according to production process data of the variable-speed variable-load intermittent operation equipment, wherein the production process data comprise production process parameters and data values corresponding to the production process parameters.
Optionally, the system further comprises:
judging the circuit state of the detection sensor, wherein the circuit state comprises the following steps: open, short and open;
when the detection sensors are in a passage state, the ultrasonic signal values detected by all the detection sensors at the current moment are correlated and matched with the production process data of the variable-speed variable-load intermittent operation equipment; and if the ultrasonic signal values detected by all the detection sensors under the current production process data are lower than normal values, judging that the detection sensors are abnormal in installation and/or fastening.
Optionally, the variable speed variable load intermittent operation device comprises: the detection sensor comprises an end cover, an end cover bolt, a rotating shaft, a detection sensor bracket and a permanent magnet;
the detection sensor is fixed on the detection sensor support, one end of the detection sensor support is fixedly connected with the end cover through the end cover bolt, and the other end of the detection sensor support is fixedly connected with the rotating shaft through the permanent magnet.
Optionally, the length of a data frame of the ultrasonic signal acquired by the detection sensor is the time of one rotation of a rotating part in the variable speed and variable load intermittent operation equipment.
The invention also provides a fault prediction method of the variable-speed variable-load intermittent operation equipment, which comprises the following steps of:
collecting ultrasonic signals generated by the running of a rotating part in variable-speed variable-load intermittent running equipment by using a detection sensor; the detection sensor is arranged on the variable-speed variable-load intermittent operation equipment and is in contact with the variable-speed variable-load intermittent operation equipment;
collecting the ultrasonic signals collected by the detection sensor through a data collecting and processing device, and transmitting the ultrasonic signals after the collection processing to a remote monitoring server;
and storing the collected ultrasonic signals through a remote monitoring server, and predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the stored ultrasonic signals.
Optionally, the method further comprises:
transmitting the production process data of the variable-speed variable-load intermittent operation equipment to the remote monitoring server through an OPC communication module;
storing the collected ultrasonic signals and the production process data of the variable-speed variable-load intermittent operation equipment, and taking the stored ultrasonic signals as the state data of the variable-speed variable-load intermittent operation equipment;
and predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment.
Optionally, the predicting whether the variable-speed variable-load intermittent operation equipment has a fault according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment comprises:
judging the circuit state of the detection sensor, wherein the circuit state comprises the following steps: open, short and open;
when the detection sensors are positioned in a passage state, acquiring ultrasonic signal values of the variable-speed variable-load intermittent operation equipment detected by all the detection sensors at the current moment from a database;
comparing the ultrasonic signal values detected by all the detection sensors at the current moment with a first comparison threshold value and/or a second comparison threshold value preset in the intelligent analysis module;
if the ultrasonic signal values detected by all the detection sensors at the current moment are smaller than a first comparison threshold value, judging that the variable-speed variable-load intermittent operation equipment is in a healthy state, and predicting that no fault exists in the variable-speed variable-load intermittent operation equipment;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a first comparison threshold value and smaller than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a primary alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a serious alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal values detected by all the detection sensors at the current moment are larger than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in an emergency fault alarm state, and the fault of the variable-speed variable-load intermittent operation equipment is predicted;
the first comparison threshold and the second comparison threshold are generated according to production process data of the variable-speed variable-load intermittent operation equipment, wherein the production process data comprise production process parameters and data values corresponding to the production process parameters.
As described above, the present invention provides a failure prediction system and method for a variable speed variable load intermittent operation device, which has the following advantages: the invention arranges the fault prediction system on the variable speed and variable load intermittent operation equipment, and can realize the display of the health/alarm state of the variable speed and variable load intermittent operation equipment on a terminal computer and a personal mobile phone terminal by an intelligent early warning method. Meanwhile, by the fault prediction system, managers can check the real-time running state of the variable-speed variable-load intermittent running equipment at any time and any place, and can receive equipment state alarm information in time through the personal mobile phone terminal, so that the aim of more scientifically and efficiently managing the equipment is fulfilled. The fault prediction method has good reusability and expandability, and is favorable for rapid popularization and application on the variable-speed variable-load intermittent operation equipment, so that the real-time state of the variable-speed variable-load intermittent operation equipment is effectively monitored.
Drawings
Fig. 1 is a schematic diagram of a hardware structure for fault detection of a variable speed and variable load intermittent operation device according to an embodiment;
FIG. 2 is a diagram illustrating exemplary detection point positions of the variable speed variable load intermittent operation apparatus;
FIG. 3 illustrates a deployment location of a detection sensor according to an embodiment;
FIG. 4 is a schematic diagram of the distance between the detecting sensor and the transmission shaft of the variable speed and load intermittent device according to one embodiment;
FIG. 5 is a schematic flow chart illustrating a failure prediction process for a variable speed and variable load intermittent device according to an embodiment;
fig. 6 is a schematic flow chart of failure prediction for a variable speed and variable load intermittent device according to another embodiment.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention. It is to be noted that the features in the following embodiments and examples may be combined with each other without conflict.
It should be noted that the drawings provided in the present embodiment are only for illustrating the basic idea of the present invention, and the components related to the present invention are only shown in the drawings rather than drawn according to the number, shape and size of the components in actual implementation, and the type, quantity and proportion of the components in actual implementation may be changed freely, and the layout of the components may be more complicated.
Referring to fig. 1 to 5, the present embodiment provides a failure prediction system for a variable speed variable load intermittent operation device, the system includes:
the detection sensor 100 is used for acquiring ultrasonic signals generated when a rotating part in variable-speed variable-load intermittent operation equipment runs; wherein, the detection sensor 100 is arranged on the variable speed and variable load intermittent operation equipment and is contacted with the variable speed and variable load intermittent operation equipment;
a data collecting and processing device 200, configured to collect the ultrasonic signals collected by the detection sensor 100, and transmit the collected ultrasonic signals to the remote monitoring server 300;
and the remote monitoring server 300 is used for storing the collected ultrasonic signals and predicting whether the variable speed variable load intermittent operation equipment has faults or not according to the stored ultrasonic signals.
In the embodiment, by deploying the fault prediction system on the variable-speed variable-load intermittent operation equipment, the health/alarm state of the variable-speed variable-load intermittent operation equipment can be displayed on a terminal computer and a personal mobile phone terminal through an intelligent early warning method. Meanwhile, through the fault prediction system in the embodiment, a manager can check the real-time running state of the variable-speed variable-load intermittent running equipment at any time and any place, and can also receive equipment state alarm information in time through the personal mobile phone terminal, so that the aim of more scientifically and efficiently managing the equipment is fulfilled.
In an exemplary embodiment, the fault prediction system of the variable speed variable load intermittent operation device further includes an OPC (ole for Process control) communication module, where the OPC communication module is disposed in the remote monitoring server 300, and is configured to transmit production Process data of the variable speed variable load intermittent operation device to the remote monitoring server 300; the remote monitoring server 300 comprises a database and an intelligent analysis module; the database is used for storing the collected ultrasonic signals, storing production process data of the variable-speed variable-load intermittent operation equipment and taking the stored ultrasonic signals as state data of the variable-speed variable-load intermittent operation equipment; the intelligent analysis module is used for predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment. As an example, specifically, the value of the ultrasonic signal received by the remote monitoring server 300 is stored in the database of the server through a network communication protocol, then the production process data (including the production process parameters and the data value corresponding to each production process parameter) of the variable speed and variable load intermittent operation equipment is stored in the database of the remote monitoring server 300 through an OPC communication module deployed in the remote monitoring server 300, then the intelligent analysis module deployed in the remote monitoring server 300 is utilized to combine the state data of the variable speed and variable load intermittent operation equipment to generate the process data, comprehensively judge the health state of the variable speed and variable load intermittent operation equipment, send out an intelligent early warning for a potential fault, and store the health state of the variable speed and variable load intermittent operation equipment and the early warning result in the database of the remote monitoring server 300.
In an exemplary embodiment, the fault prediction system of the variable speed variable load intermittent operation equipment further comprises an early warning device, wherein the early warning device is connected with the intelligent analysis module and is used for sending out an early warning signal according to a prediction result of the intelligent analysis module; wherein the early warning signal comprises: acoustic signals, optical signals, text messages, and/or WeChat popup windows. As an example, specifically, the remote monitoring server 300 sends the health status of the device to an on-site production Control system such as a dcs (distributed Control system) Control system through an OPC communication protocol, and sends the early warning result to an early warning device deployed on the site through a network communication protocol, where the early warning device sends out an alarm signal in various forms such as sound, light, and the like; meanwhile, the alarm signal is pushed to a mobile phone of an equipment manager in modes of short messages, WeChat popup windows and the like.
According to the above description, in an exemplary embodiment, the process of predicting whether the variable-speed variable-load intermittent operation device has a fault by the intelligent analysis module according to the state data and the production process data of the variable-speed variable-load intermittent operation device includes:
determining a circuit state of the detection sensor 100, the circuit state including: open, short and open;
when the detection sensor 100 is in a passage state, acquiring ultrasonic signal values of the variable speed and variable load intermittent operation equipment detected by all the detection sensors 100 at the current moment from a database;
comparing the ultrasonic signal values detected by all the detection sensors 100 at the current moment with a first comparison threshold value and/or a second comparison threshold value preset in the intelligent analysis module;
if all the ultrasonic signal values detected by all the detection sensors 100 at the current moment are smaller than a first comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a healthy state, and the variable-speed variable-load intermittent operation equipment is predicted to have no fault;
if the ultrasonic signal value detected by the partial detection sensor 100 at the current moment is greater than a first comparison threshold value and smaller than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a primary alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal value detected by the partial detection sensor 100 at the current moment is greater than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a serious alarm state, and the fault of the variable-speed variable-load intermittent operation equipment is predicted;
if the ultrasonic signal values detected by all the detection sensors 100 at the current moment are greater than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in an emergency fault alarm state, and the fault of the variable-speed variable-load intermittent operation equipment is predicted;
the first comparison threshold and the second comparison threshold are generated according to production process data of the variable-speed variable-load intermittent operation equipment, wherein the production process data comprise production process parameters and data values corresponding to the production process parameters.
After the fault judgment is completed, the health state/alarm state result can be stored in the database of the remote monitoring server 300 in real time and permanently stored, and under the condition that the terminal computer of the relevant management personnel and the personal mobile phone terminal obtain authorization, the health state/alarm state of the variable speed variable load intermittent operation equipment can be checked in real time through the Ethernet network.
According to the above description, in an exemplary embodiment, the failure prediction system of the variable speed variable load intermittent operation apparatus further includes: determining a circuit state of the detection sensor 100, the circuit state including: open, short and open; when the detection sensors 100 are in a passage state, correlating and matching the ultrasonic signal values detected by all the detection sensors 100 at the current moment with the production process data of the variable-speed variable-load intermittent operation equipment; and if the ultrasonic signal values detected by all the detection sensors 100 under the current production process data are lower than normal values, judging that the detection sensors 100 are abnormal in installation and/or fastening, and carrying out intelligent alarm.
In an exemplary embodiment, the variable speed variable load intermittent operation apparatus includes: the detection sensor comprises an end cover, an end cover bolt, a rotating shaft, a detection sensor 100 bracket and a permanent magnet; the detection sensor 100 is fixed on the detection sensor 100 support, one end of the detection sensor 100 support is fixedly connected with the end cover through the end cover bolt, and the other end of the detection sensor 100 support is fixedly connected with the rotating shaft through the permanent magnet. In this embodiment, the deployment position of the detection sensor 100 is shown in fig. 3, wherein the detection sensor 100 may be a rotation speed sensor.
In some exemplary embodiments, the length of the data frame for acquiring the ultrasonic signal by the detection sensor 100 is the time of one rotation of the rotating component in the variable speed variable load intermittent operation device. As shown in fig. 4, there is a distance between the detection sensor 100 and the rotating shaft of the variable speed and variable load intermittent operation device, and when the distance between the detection sensor 100 and the variable speed and variable load intermittent operation device exceeds or is less than the distance, it may cause the monitoring data of the detection sensor 100 to be incorrect; wherein, in this application embodiment, the pivot interval that detects sensor 100 and variable speed become to carry intermittent type formula operation equipment can set up according to actual conditions, and end cover bolt hole central circle diameter D is greater than pivot diameter D.
In one embodiment, as shown in fig. 2 to 5, a failure prediction system for a variable speed and variable load intermittent operation device is provided, which comprises: the system comprises a detection sensor 100, a sensor installation accessory, a data collection processing device 200, an OPC communication module, a remote monitoring server 300 and an early warning device; the detection sensor 100, the sensor installation accessory, the data collection processing device 200 and the early warning device are deployed on site, the OPC communication module and the remote monitoring server 300 are deployed in a machine room, and the intelligent early warning algorithm is deployed in the monitoring server. As shown in fig. 2, the detection sensor 100 is fixed to a side surface of a rotating shaft of the variable speed variable load intermittent operation device or an end cover of the variable speed variable load intermittent operation device via a sensor mounting fitting, so that the detection sensor 100 is rigidly connected or in contact with the variable speed variable load intermittent operation device. As shown in fig. 3, the sensor mounting fitting includes a sensor bracket, a permanent magnet, and an end cap bolt; the detection sensor 100 is fixed on the detection sensor 100 support, one end of the detection sensor 100 support is fixedly connected with the end cover through an end cover bolt, and the other end of the detection sensor 100 support is fixedly connected with the rotating shaft through a permanent magnet. Among them, the detection sensor 100 may be a rotation speed sensor.
According to the mounting means of detecting sensor 100, set up n detecting sensor 100 respectively on the bearing end cover bolt of every pivot, then judge detecting sensor 100's circuit state, the circuit state includes: open, short and open; and when the detection sensor 100 is in a passage state, acquiring ultrasonic signals generated by friction when a rotating part in the variable speed variable load intermittent operation equipment runs by using the detection sensor 100, and transmitting the ultrasonic signals acquired by all the detection sensors 100 at the current moment to the data collection processing device 200 through a communication network. The length of the data frame of the detection sensor 100 needs to cover a complete time range of one rotation of mechanical transmission components such as a variable speed variable load intermittent operation equipment shafting, a bearing, a gear and the like, and as an example, the length of the data frame of the detection sensor 100 in the embodiment of the present application is 2 seconds.
The data aggregation processing device 200 aggregates the signals collected by the n detection sensors 100 in the synchronous scanning mode, and then packages and transmits the information to the remote monitoring server 300 through the communication network. The OPC communication module deployed in the remote monitoring server 300 reads the device production process parameters and the corresponding parameter data in the DCS system and the plc (programmable Logic controller) through a plurality of OPC communication protocols. In the embodiment of the application, in order to reduce the resource occupation of the DCS and the PLC, the period for reading data can be in the second level; for example, every 5 seconds, the production process parameters and corresponding parameter data within 5 seconds are transmitted to the remote monitoring server 300 in a packaged manner through the communication network. Aiming at the characteristics of high generation frequency of process parameters and process data, large information amount and serious dependence on acquisition time, the invention adopts a time sequence big data solution scheme and realizes excellent query performance through a time sequence function, so that the process parameters and the process data can be efficiently stored and rapidly processed, the storage space is halved compared with a relational database, and the query speed is greatly improved.
Then, the intelligent analysis module in the remote monitoring server 300 is utilized to predict whether the variable speed and variable load intermittent operation equipment has a fault according to the state data and the production process data of the variable speed and variable load intermittent operation equipment, and the method comprises the following steps: determining a circuit state of the detection sensor 100, the circuit state including: open, short and open; when the detection sensor 100 is in a passage state, acquiring ultrasonic signal values of the variable speed and variable load intermittent operation equipment detected by all the detection sensors 100 at the current moment from a database; and comparing the ultrasonic signal values detected by all the detection sensors 100 at the current moment with a first comparison threshold and/or a second comparison threshold preset in the intelligent analysis module. If all the ultrasonic signal values detected by all the detection sensors 100 at the current moment are smaller than the first comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a healthy state, and the variable-speed variable-load intermittent operation equipment is predicted to have no fault. If the ultrasonic signal value detected by the partial detection sensor 100 at the current moment is greater than the first comparison threshold value and smaller than the second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a primary alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault. If the ultrasonic signal value detected by the partial detection sensor 100 at the current moment is greater than the second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a serious alarm state, and the fault of the variable-speed variable-load intermittent operation equipment is predicted. If the ultrasonic signal values detected by all the detection sensors 100 at the current moment are greater than the second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in an emergency fault alarm state, and the fault of the variable-speed variable-load intermittent operation equipment is predicted. The first comparison threshold and the second comparison threshold are generated according to production process data of the variable-speed variable-load intermittent operation equipment, wherein the production process data comprise production process parameters and data values corresponding to the production process parameters.
According to the above description, when the detection sensor 100 is in the on-state, the ultrasonic signal values detected by all the detection sensors 100 at the current time can be associated and matched with the production process data of the variable speed variable load intermittent operation equipment; and if the ultrasonic signal values detected by all the detection sensors 100 under the current production process data are lower than normal values, judging that the detection sensors 100 are abnormal in installation and/or fastening, and carrying out intelligent alarm. As an example, the remote monitoring server 300 sends the health status of the device to a field production control system such as a DCS control system through an OPC communication protocol, and sends the early warning result to an early warning device deployed on the field through a network communication protocol, where the early warning device sends out an alarm signal in various forms such as sound, light, and the like; meanwhile, the alarm signal is pushed to a mobile phone of an equipment manager in modes of short messages, WeChat popup windows and the like.
In summary, the invention can display the health/alarm state of the variable-speed variable-load intermittent operation equipment on the terminal computer and the personal mobile phone terminal by the intelligent early warning method by deploying the fault prediction system on the variable-speed variable-load intermittent operation equipment. Meanwhile, through the fault prediction system in the embodiment, a manager can check the real-time running state of the variable-speed variable-load intermittent running equipment at any time and any place, and can also receive equipment state alarm information in time through the personal mobile phone terminal, so that the aim of more scientifically and efficiently managing the equipment is fulfilled.
As shown in fig. 6, the present invention also provides a failure prediction method for a variable speed variable load intermittent operation apparatus, the method comprising the steps of:
s10, collecting ultrasonic signals generated when a rotating part in variable-speed variable-load intermittent operation equipment runs by using a detection sensor; the detection sensor is arranged on the variable-speed variable-load intermittent operation equipment and is in contact with the variable-speed variable-load intermittent operation equipment;
s20, collecting the ultrasonic signals collected by the detection sensor through a data collecting and processing device, and transmitting the ultrasonic signals after the collection processing to a remote monitoring server;
and S30, storing the collected ultrasonic signals through the remote monitoring server, and predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the stored ultrasonic signals.
In the embodiment, by deploying the fault prediction system on the variable-speed variable-load intermittent operation equipment, the health/alarm state of the variable-speed variable-load intermittent operation equipment can be displayed on a terminal computer and a personal mobile phone terminal through an intelligent early warning method. Meanwhile, through the fault prediction system in the embodiment, a manager can check the real-time running state of the variable-speed variable-load intermittent running equipment at any time and any place, and can also receive equipment state alarm information in time through the personal mobile phone terminal, so that the aim of more scientifically and efficiently managing the equipment is fulfilled.
In an exemplary embodiment, the method further comprises: transmitting the production process data of the variable-speed variable-load intermittent operation equipment to the remote monitoring server through an OPC communication module; storing the collected ultrasonic signals and the production process data of the variable-speed variable-load intermittent operation equipment, and taking the stored ultrasonic signals as the state data of the variable-speed variable-load intermittent operation equipment; and predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment. Specifically, as an example, an ultrasonic signal value received by a remote monitoring server is stored in a database of the server through a network communication protocol, then production process data (including production process parameters and data values corresponding to each production process parameter) of variable-speed variable-load intermittent operation equipment is stored in the database of the remote monitoring server through an OPC communication module deployed in the remote monitoring server, then an intelligent analysis module deployed in the remote monitoring server is utilized to combine the state data of the variable-speed variable-load intermittent operation equipment and generate process data, comprehensively judge the health state of the variable-speed variable-load intermittent operation equipment, send out intelligent early warning for potential faults, and store the health state and early warning results of the variable-speed variable-load intermittent operation equipment in the database of the remote monitoring server.
In an exemplary embodiment, the intelligent analysis system further comprises an early warning device, wherein the early warning device is connected with the intelligent analysis module and used for sending out an early warning signal according to a prediction result of the intelligent analysis module; wherein the early warning signal comprises: acoustic signals, optical signals, text messages, and/or WeChat popup windows. As an example, specifically, the remote monitoring server sends the health state of the device to an on-site production Control system such as a dcs (distributed Control system) Control system through an OPC communication protocol, and sends an early warning result to an early warning device deployed on the site through a network communication protocol, and the early warning device sends out an alarm signal in various forms such as sound, light, and the like; meanwhile, the alarm signal is pushed to a mobile phone of an equipment manager in modes of short messages, WeChat popup windows and the like.
According to the above description, in an exemplary embodiment, the process of predicting whether the variable speed variable load intermittent operation device has a fault according to the state data and the production process data of the variable speed variable load intermittent operation device includes:
judging the circuit state of the detection sensor, wherein the circuit state comprises the following steps: open, short and open;
when the detection sensors are positioned in a passage state, acquiring ultrasonic signal values of the variable-speed variable-load intermittent operation equipment detected by all the detection sensors at the current moment from a database;
comparing the ultrasonic signal values detected by all the detection sensors at the current moment with a first comparison threshold value and/or a second comparison threshold value preset in the intelligent analysis module;
if the ultrasonic signal values detected by all the detection sensors at the current moment are smaller than a first comparison threshold value, judging that the variable-speed variable-load intermittent operation equipment is in a healthy state, and predicting that no fault exists in the variable-speed variable-load intermittent operation equipment;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a first comparison threshold value and smaller than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a primary alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a serious alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal values detected by all the detection sensors at the current moment are larger than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in an emergency fault alarm state, and the fault of the variable-speed variable-load intermittent operation equipment is predicted;
the first comparison threshold and the second comparison threshold are generated according to production process data of the variable-speed variable-load intermittent operation equipment, wherein the production process data comprise production process parameters and data values corresponding to the production process parameters.
After the fault judgment is completed, the health state/alarm state result can be stored in a database of the remote monitoring server in real time for permanent storage, and the health state/alarm state of the variable speed variable load intermittent operation equipment can be checked in real time through the Ethernet under the condition that a terminal computer of a related manager and a personal mobile phone terminal are authorized.
According to the above, in an exemplary embodiment, the method further includes: judging the circuit state of the detection sensor, wherein the circuit state comprises the following steps: open, short and open; when the detection sensors are in a passage state, the ultrasonic signal values detected by all the detection sensors at the current moment are correlated and matched with the production process data of the variable-speed variable-load intermittent operation equipment; and if the ultrasonic signal values detected by all the detection sensors under the current production process data are lower than normal values, judging that the detection sensors are abnormal in installation and/or fastening, and carrying out intelligent alarm.
In an exemplary embodiment, the variable speed variable load intermittent operation apparatus includes: the detection sensor comprises an end cover, an end cover bolt, a rotating shaft, a detection sensor bracket and a permanent magnet; the detection sensor is fixed on the detection sensor support, one end of the detection sensor support is fixedly connected with the end cover through the end cover bolt, and the other end of the detection sensor support is fixedly connected with the rotating shaft through the permanent magnet. In this embodiment, the deployment position of the detection sensor is shown in fig. 3, wherein the detection sensor may be a rotation speed sensor.
In some exemplary embodiments, the length of the data frame for acquiring the ultrasonic signal by the detection sensor is the time for rotating the rotating part in the variable speed variable load intermittent operation equipment for one rotation. As shown in fig. 4, there is a distance between the detection sensor and the rotating shaft of the variable speed and variable load intermittent operation device, and when the distance between the detection sensor and the variable speed and variable load intermittent operation device exceeds or is less than the distance, it may cause the monitoring data of the detection sensor to be incorrect; wherein, in this application embodiment, the pivot interval that detects sensor and variable speed become to carry intermittent type formula operation equipment can set up according to actual conditions, and end cover bolt hole centre circle diameter D is greater than pivot diameter D.
In one embodiment, as shown in fig. 2 to 5, a method for predicting a failure of a variable speed variable load intermittent operation apparatus is provided, comprising the steps of: the detection sensor, the sensor installation accessory, the data collection processing device and the early warning device are deployed on site, the OPC communication module and the remote monitoring server are deployed in a machine room, and the intelligent early warning algorithm is deployed in the monitoring server. As shown in fig. 2, the detection sensor is fixed on the side of the rotating shaft of the variable speed variable load intermittent operation device or the end cover of the variable speed variable load intermittent operation device via a sensor mounting fitting, so that the detection sensor and the variable speed variable load intermittent operation device are rigidly connected or contacted. As shown in fig. 3, the sensor mounting fitting includes a sensor bracket, a permanent magnet, and an end cap bolt; the detection sensor is fixed on the detection sensor support, one end of the detection sensor support is fixedly connected with the end cover through an end cover bolt, and the other end of the detection sensor support is fixedly connected with the rotating shaft through a permanent magnet. Wherein, the detection sensor can be a rotation speed sensor.
According to the mounting means who detects the sensor, set up n detection sensor respectively on the bearing end cover bolt of every pivot, then judge the circuit state that detects the sensor, the circuit state includes: open, short and open; and when the detection sensor is in a passage state, the detection sensor is used for collecting ultrasonic signals generated by friction when a rotating part in the variable-speed variable-load intermittent operation equipment runs, and the ultrasonic signals collected by all the detection sensors at the current moment are transmitted to the data collection processing device through the communication network. The length of the data frame of the detection sensor needs to cover a complete time range of one rotation of mechanical transmission parts such as a variable speed variable load intermittent operation equipment shafting, a bearing, a gear and the like, and as an example, the length of the data frame of the detection sensor in the embodiment of the application is 2 seconds.
The data collecting and processing device collects and processes the signals collected by the n detection sensors in a synchronous scanning mode, and then packs and transmits the information to the remote monitoring server through the communication network. An OPC communication module deployed in a remote monitoring server reads equipment production process parameters and corresponding parameter data in a DCS (distributed control system) and a PLC (programmable Logic controller) through a plurality of OPC communication protocols. In the embodiment of the application, in order to reduce the resource occupation of the DCS and the PLC, the period for reading data can be in the second level; for example, every 5 seconds, the production process parameters and corresponding parameter data within 5 seconds are packaged and transmitted to the remote monitoring server through the communication network. Aiming at the characteristics of high generation frequency of process parameters and process data, large information amount and serious dependence on acquisition time, the invention adopts a time sequence big data solution scheme and realizes excellent query performance through a time sequence function, so that the process parameters and the process data can be efficiently stored and rapidly processed, the storage space is halved compared with a relational database, and the query speed is greatly improved.
Then, an intelligent analysis module in the remote monitoring server is utilized to predict whether the variable-speed variable-load intermittent operation equipment has faults or not according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment, and the method comprises the following steps: judging the circuit state of the detection sensor, wherein the circuit state comprises the following steps: open, short and open; when the detection sensors are positioned in a passage state, acquiring ultrasonic signal values of the variable-speed variable-load intermittent operation equipment detected by all the detection sensors at the current moment from a database; and comparing the ultrasonic signal values detected by all the detection sensors at the current moment with a first comparison threshold value and/or a second comparison threshold value preset in the intelligent analysis module. And if the ultrasonic signal values detected by all the detection sensors at the current moment are smaller than a first comparison threshold value, judging that the variable-speed variable-load intermittent operation equipment is in a healthy state, and predicting that no fault exists in the variable-speed variable-load intermittent operation equipment. And if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a first comparison threshold and smaller than a second comparison threshold, judging that the variable-speed variable-load intermittent operation equipment is in a primary alarm state, and predicting that the variable-speed variable-load intermittent operation equipment has a fault. And if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a second comparison threshold value, judging that the variable-speed variable-load intermittent operation equipment is in a serious alarm state, and predicting that the variable-speed variable-load intermittent operation equipment has a fault. And if the ultrasonic signal values detected by all the detection sensors at the current moment are larger than a second comparison threshold value, judging that the variable-speed variable-load intermittent operation equipment is in an emergency fault alarm state, and predicting that the variable-speed variable-load intermittent operation equipment has faults. The first comparison threshold and the second comparison threshold are generated according to production process data of the variable-speed variable-load intermittent operation equipment, wherein the production process data comprise production process parameters and data values corresponding to the production process parameters.
According to the above description, when the detection sensors are in the on-state, the ultrasonic signal values detected by all the detection sensors at the current moment can be associated and matched with the production process data of the variable-speed variable-load intermittent operation equipment; and if the ultrasonic signal values detected by all the detection sensors under the current production process data are lower than normal values, judging that the detection sensors are abnormal in installation and/or fastening, and carrying out intelligent alarm. As an example, the remote monitoring server sends the health state of the equipment to a field production control system such as a DCS control system and the like through an OPC communication protocol, and sends an early warning result to an early warning device deployed on the field through a network communication protocol, and the early warning device sends out an alarm signal in various forms such as sound, light, and the like; meanwhile, the alarm signal is pushed to a mobile phone of an equipment manager in modes of short messages, WeChat popup windows and the like.
In summary, the invention can display the health/alarm state of the variable-speed variable-load intermittent operation equipment on the terminal computer and the personal mobile phone terminal by the intelligent early warning method by deploying the fault prediction method on the variable-speed variable-load intermittent operation equipment. Meanwhile, by the fault prediction method in the embodiment, a manager can check the real-time running state of the variable-speed variable-load intermittent running equipment at any time and any place, and can receive equipment state alarm information in time through the personal mobile phone terminal, so that the aim of more scientifically and efficiently managing the equipment is fulfilled. The fault prediction method has good reusability and expandability, and is favorable for rapid popularization and application on the variable-speed variable-load intermittent operation equipment, so that the real-time state of the variable-speed variable-load intermittent operation equipment is effectively monitored.
In summary, the fault prediction system is deployed on the variable-speed variable-load intermittent operation equipment, and the health/alarm state of the variable-speed variable-load intermittent operation equipment can be displayed on the terminal computer and the personal mobile phone terminal through an intelligent early warning method. Meanwhile, by the fault prediction system, managers can check the real-time running state of the variable-speed variable-load intermittent running equipment at any time and any place, and can receive equipment state alarm information in time through the personal mobile phone terminal, so that the aim of more scientifically and efficiently managing the equipment is fulfilled. The fault prediction method has good reusability and expandability, and is favorable for rapid popularization and application on the variable-speed variable-load intermittent operation equipment, so that the real-time state of the variable-speed variable-load intermittent operation equipment is effectively monitored. Therefore, the invention effectively overcomes various defects in the prior art and has high industrial utilization value.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
The structures, proportions, and dimensions shown in the drawings and described in the specification are for illustrative purposes only and are not intended to limit the scope of the present invention, which is defined by the claims, but rather by the claims, and are not intended to limit the scope of the present invention. In addition, the terms "upper", "lower", "left", "right", "middle" and "one" used in the present specification are for clarity of description, and are not intended to limit the scope of the present invention, and the relative relationship between the terms and the terms is not to be construed as a scope of the present invention.
It should be understood that although the terms first, second, third, etc. may be used to describe preset ranges, etc. in embodiments of the present invention, these preset ranges should not be limited to these terms. These terms are only used to distinguish preset ranges from each other. For example, the first preset range may also be referred to as a second preset range, and similarly, the second preset range may also be referred to as the first preset range, without departing from the scope of the embodiments of the present invention.
Claims (10)
1. A failure prediction system for a variable speed, variable load intermittently operated apparatus, said system comprising:
the detection sensor is used for acquiring ultrasonic signals generated when a rotating component in the variable-speed variable-load intermittent operation equipment runs; the detection sensor is arranged on the variable-speed variable-load intermittent operation equipment and is in contact with the variable-speed variable-load intermittent operation equipment;
the data collecting and processing device is used for collecting and processing the ultrasonic signals collected by the detection sensor and transmitting the collected and processed ultrasonic signals to the remote monitoring server;
and the remote monitoring server is used for storing the collected ultrasonic signals and predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the stored ultrasonic signals.
2. The system for predicting the failure of the variable-speed variable-load intermittent operation equipment according to claim 1, further comprising an OPC communication module, wherein the OPC communication module is arranged in the remote monitoring server and is used for transmitting production process data of the variable-speed variable-load intermittent operation equipment to the remote monitoring server;
the remote monitoring server comprises a database and an intelligent analysis module;
the database is used for storing the collected ultrasonic signals, storing production process data of the variable-speed variable-load intermittent operation equipment and taking the stored ultrasonic signals as state data of the variable-speed variable-load intermittent operation equipment;
the intelligent analysis module is used for predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment.
3. The fault prediction system of variable speed variable load intermittent operation equipment as claimed in claim 2, characterized in that the system further comprises an early warning device, the early warning device is connected with the intelligent analysis module and is used for sending out an early warning signal according to the prediction result of the intelligent analysis module; wherein the early warning signal comprises: acoustic signals, optical signals, text messages, and/or WeChat popup windows.
4. The system for predicting the fault of the variable-speed variable-load intermittent operation equipment according to claim 2, wherein the process that the intelligent analysis module predicts whether the fault of the variable-speed variable-load intermittent operation equipment exists according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment comprises the following steps:
judging the circuit state of the detection sensor, wherein the circuit state comprises the following steps: open, short and open;
when the detection sensors are positioned in a passage state, acquiring ultrasonic signal values of the variable-speed variable-load intermittent operation equipment detected by all the detection sensors at the current moment from a database;
comparing the ultrasonic signal values detected by all the detection sensors at the current moment with a first comparison threshold value and/or a second comparison threshold value preset in the intelligent analysis module;
if the ultrasonic signal values detected by all the detection sensors at the current moment are smaller than a first comparison threshold value, judging that the variable-speed variable-load intermittent operation equipment is in a healthy state, and predicting that no fault exists in the variable-speed variable-load intermittent operation equipment;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a first comparison threshold value and smaller than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a primary alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a serious alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal values detected by all the detection sensors at the current moment are larger than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in an emergency fault alarm state, and the fault of the variable-speed variable-load intermittent operation equipment is predicted;
the first comparison threshold and the second comparison threshold are generated according to production process data of the variable-speed variable-load intermittent operation equipment, wherein the production process data comprise production process parameters and data values corresponding to the production process parameters.
5. The failure prediction system of a variable speed variable load intermittent operation apparatus according to claim 1 or 4, characterized by further comprising:
judging the circuit state of the detection sensor, wherein the circuit state comprises the following steps: open, short and open;
when the detection sensors are in a passage state, the ultrasonic signal values detected by all the detection sensors at the current moment are correlated and matched with the production process data of the variable-speed variable-load intermittent operation equipment; and if the ultrasonic signal values detected by all the detection sensors under the current production process data are lower than normal values, judging that the detection sensors are abnormal in installation and/or fastening.
6. The failure prediction system of a variable speed variable load intermittent operation device according to claim 1, wherein the variable speed variable load intermittent operation device comprises: the detection sensor comprises an end cover, an end cover bolt, a rotating shaft, a detection sensor bracket and a permanent magnet;
the detection sensor is fixed on the detection sensor support, one end of the detection sensor support is fixedly connected with the end cover through the end cover bolt, and the other end of the detection sensor support is fixedly connected with the rotating shaft through the permanent magnet.
7. The system according to claim 1, wherein the length of the frame of the ultrasonic signal acquired by the detection sensor is the time of one rotation of the rotating member in the variable speed variable load intermittent operation device.
8. A method of predicting a failure of a variable speed variable load intermittent operation apparatus, the method comprising the steps of:
collecting ultrasonic signals generated by the running of a rotating part in variable-speed variable-load intermittent running equipment by using a detection sensor; the detection sensor is arranged on the variable-speed variable-load intermittent operation equipment and is in contact with the variable-speed variable-load intermittent operation equipment;
collecting the ultrasonic signals collected by the detection sensor through a data collecting and processing device, and transmitting the ultrasonic signals after the collection processing to a remote monitoring server;
and storing the collected ultrasonic signals through a remote monitoring server, and predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the stored ultrasonic signals.
9. The method of predicting a failure of a variable speed variable load intermittent operation device according to claim 1, further comprising:
transmitting the production process data of the variable-speed variable-load intermittent operation equipment to the remote monitoring server through an OPC communication module;
storing the collected ultrasonic signals and the production process data of the variable-speed variable-load intermittent operation equipment, and taking the stored ultrasonic signals as the state data of the variable-speed variable-load intermittent operation equipment;
and predicting whether the variable-speed variable-load intermittent operation equipment has faults or not according to the state data and the production process data of the variable-speed variable-load intermittent operation equipment.
10. The method for predicting the failure of the variable speed variable load intermittent operation equipment according to claim 9, wherein the step of predicting whether the variable speed variable load intermittent operation equipment has the failure according to the state data and the production process data of the variable speed variable load intermittent operation equipment comprises the following steps:
judging the circuit state of the detection sensor, wherein the circuit state comprises the following steps: open, short and open;
when the detection sensors are positioned in a passage state, acquiring ultrasonic signal values of the variable-speed variable-load intermittent operation equipment detected by all the detection sensors at the current moment from a database;
comparing the ultrasonic signal values detected by all the detection sensors at the current moment with a first comparison threshold value and/or a second comparison threshold value preset in the intelligent analysis module;
if the ultrasonic signal values detected by all the detection sensors at the current moment are smaller than a first comparison threshold value, judging that the variable-speed variable-load intermittent operation equipment is in a healthy state, and predicting that no fault exists in the variable-speed variable-load intermittent operation equipment;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a first comparison threshold value and smaller than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a primary alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal value detected by the partial detection sensor at the current moment is greater than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in a serious alarm state, and the variable-speed variable-load intermittent operation equipment is predicted to have a fault;
if the ultrasonic signal values detected by all the detection sensors at the current moment are larger than a second comparison threshold value, the variable-speed variable-load intermittent operation equipment is judged to be in an emergency fault alarm state, and the fault of the variable-speed variable-load intermittent operation equipment is predicted;
the first comparison threshold and the second comparison threshold are generated according to production process data of the variable-speed variable-load intermittent operation equipment, wherein the production process data comprise production process parameters and data values corresponding to the production process parameters.
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