CN114215779A - Fault predicting and diagnosing method and device for industrial fan - Google Patents
Fault predicting and diagnosing method and device for industrial fan Download PDFInfo
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- CN114215779A CN114215779A CN202111435878.4A CN202111435878A CN114215779A CN 114215779 A CN114215779 A CN 114215779A CN 202111435878 A CN202111435878 A CN 202111435878A CN 114215779 A CN114215779 A CN 114215779A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
- F04D27/001—Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring
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Abstract
The invention provides a method and a device for predicting and diagnosing faults of an industrial fan, wherein the method comprises the following steps: acquiring industrial fan data; carrying out fast Fourier transform on the obtained vibration data and carrying out spectrum analysis to obtain a first data set; comparing and diagnosing by combining a preset data set according to the first data set, the temperature data of the industrial fan and the scrap iron content data to obtain a diagnosis result; and sending the diagnosis result of the first data set to a WIFI serial server so that the WIFI serial server sends the first data set and the diagnosis result to a central control information system. Compared with the prior art, the method can realize real-time detection in the operation process of the industrial fan; the acquired data is comprehensive, the maintenance personnel can timely know the working state of the industrial fan, the time consumed by the maintenance personnel in diagnosing the industrial fan is reduced, the fault is timely predicted and diagnosed, and the purposes of saving the maintenance cost and reducing the rejection rate of the industrial fan are achieved.
Description
Technical Field
The invention relates to the field of fault prediction and diagnosis, in particular to a fault prediction and diagnosis method and device for an industrial fan.
Background
Oversized industrial fans are now widely used in various production workshops and warehouses. The installation mode of super large industrial fan is suspension type usually, installs in the top of factory building, and the height apart from the ground is more than ten meters, and the below of super large industrial fan is the operation region. The fans are maintained mainly by once-a-year oil replacement and the like, but according to recent maintenance data, a large number of oversized industrial fan main machines are scrapped due to faults every year, and the faults are basically formed by the following reasons after analysis: after the gear is abraded, scrap iron is deposited to a bottom bearing, so that the bearing is abraded, and then deflection occurs, so that the gear abrasion is further aggravated; after the motor bearing enters dust and scrap iron to aggravate abrasion, the abrasion of the bearing is more serious because the abrasion is not found in time, and finally the motor is damaged because the motor shaft is cracked by the retainer and deflects.
At present, the method for avoiding faults comprises the steps of regularly replacing the traveling cable, replacing lubricating oil in a reduction gearbox of a host machine in maintenance, checking whether a fastening part is loosened, whether fan blades are collided, cleaning accumulated dust and the like. However, since maintenance work using a lift truck is required, the lift truck passes through the gap between the blades when it is raised to the position of the main machine, and thus inspection in an operating state cannot be performed, and detection of some faults or maintenance cannot be completed or omitted, so that it is difficult to prescribe medicines for the problems of the fan, and technicians or managers easily miss the symptoms of faults that should be found.
Disclosure of Invention
The invention provides a fault predicting and diagnosing method and device for an industrial fan, which aim to solve the technical problem of automatically predicting and diagnosing faults in the running state of the industrial fan.
In order to solve the above technical problem, an embodiment of the present invention provides a method for predicting and diagnosing a fault of an industrial fan, including:
acquiring scrap iron content data, vibration data of the industrial fan and temperature data of the industrial fan within preset time in a speed reducer of the industrial fan;
carrying out fast Fourier transform on the obtained vibration data and carrying out frequency spectrum analysis to obtain a first data set;
comparing the first data set, the scrap iron content data and the temperature data with a preset data set and diagnosing the state of the industrial fan to obtain a diagnosis result;
and sending the first data set and the diagnosis result to a WIFI serial server so that the WIFI serial server sends the first data set and the diagnosis result to a central control information system.
Further, the obtained vibration data is subjected to fast fourier transform and spectral analysis to obtain a first data set, specifically:
and carrying out fast Fourier transform on the acquired vibration data to obtain corresponding frequency spectrum data in a preset time period, and integrating the frequency spectrum data to obtain a corresponding first data set.
Further, the state of the industrial fan is compared and diagnosed with a preset data set according to the first data set, the scrap iron content data and the temperature data, and a diagnosis result is obtained, specifically:
comparing the first data set with the preset data set in real time, and judging whether the first data set has abnormal wave crests;
when the abnormal wave peak does not appear in the first data set, confirming no fault; when the abnormal wave crest appears in the first data set, determining a corresponding fault type according to the type of the abnormal wave crest;
and comparing the scrap iron content data, the temperature data and the preset data set in real time, and obtaining the temperature state of the industrial fan and the on-off state of a reduction gearbox of the industrial fan according to a comparison result.
Further, the obtaining of the iron content data in the reduction gearbox of the industrial fan within the preset time, the vibration data of the industrial fan and the temperature data of the industrial fan are specifically as follows:
iron fillings content data in the time of presetting in the gear box of obtaining industrial fan through lubricating oil iron fillings sensor, acquire through acoustoelectric transducer industrial fan's vibrations data and acquire through temperature sensor industrial fan's temperature data.
Further, acquire the iron fillings content data in the reduction gearbox of industrial fan in the preset time through lubricating oil iron fillings sensor, specifically do:
detecting the scrap iron content in the reduction gearbox within a preset time through the induction part of the lubricating oil scrap iron sensor to obtain scrap iron content data; the lubricating oil scrap iron sensor is arranged on a host machine reduction gearbox of the industrial fan in an oil seal mode.
Furthermore, the sensing surface of the acoustoelectric transducer and the sensing surface of the temperature sensor are attached to a host motor of the industrial fan.
Further, after the obtaining the diagnosis result, the method further comprises: sending heartbeat instructions to the WIFI serial server every other first preset time so that the WIFI serial server sends heartbeat packets to the central control information system every other first preset time.
Correspondingly, the embodiment of the invention also provides a fault predicting and diagnosing device of the industrial fan, which comprises a signal acquisition and analysis system and a central control information system; the signal acquisition and analysis system comprises a lubricating oil scrap iron sensor, an acoustoelectric transducer sensor, a temperature sensor, an embedded computer and a WIFI serial port server;
the lubricating oil scrap iron sensor is used for acquiring scrap iron content data in a preset time in a speed reducer of the industrial fan and sending the scrap iron content data to the embedded computer;
the sound-electricity transducer sensor is used for acquiring vibration data of the industrial fan in real time and sending the vibration data to the embedded computer;
the temperature sensor is used for acquiring temperature data of the industrial fan in real time and sending the temperature data to the embedded computer;
the embedded computer is used for performing fast Fourier transform on the obtained vibration data and performing spectrum analysis to obtain a first data set; comparing the first data set, the scrap iron content data and the temperature data with a preset data set and diagnosing the state of the industrial fan to obtain a diagnosis result; sending the first data set and the diagnosis result to the WIFI serial server, and sending heartbeat instructions to the WIFI serial server at preset time intervals;
the WIFI serial port server is used for sending the first data set and the diagnosis result to a central control information system, and sending heartbeat packets to the central control information system at intervals of the first preset time.
Further, the central control information system comprises a tower server, a display, a keyboard, a mouse and a wireless switch; wherein the content of the first and second substances,
the wireless switch is used for providing network access for the signal acquisition and analysis system;
the tower server is used for storing the first data set into a database;
the display is used for displaying information of the industrial fan;
the keyboard and the mouse are used for information interaction with an administrator.
Further, the display is used for displaying information of the industrial fan, and specifically comprises: the display is used for displaying the first data set, the diagnosis result, distribution information of the industrial fans in workshop buildings, running states, running time, real-time health conditions, historical maintenance records and next maintenance time.
Compared with the prior art, the embodiment of the invention has the following beneficial effects:
the embodiment of the invention provides a method and a device for predicting and diagnosing faults of an industrial fan, wherein the method comprises the following steps: acquiring industrial fan data; carrying out fast Fourier transform on the obtained vibration data and carrying out spectrum analysis to obtain a first data set; comparing and diagnosing by combining a preset data set according to the first data set, the temperature data of the industrial fan and the scrap iron content data to obtain a diagnosis result; and sending the diagnosis result of the first data set to a WIFI serial server so that the WIFI serial server sends the first data set and the diagnosis result to a central control information system. Compared with the prior art, the method can realize real-time detection in the operation process of the industrial fan; the obtained data comprise scrap iron content data, vibration data and temperature data, and the method is comprehensive, so that maintenance personnel can know the working state of the industrial fan, the time consumed by the maintenance personnel in diagnosing the industrial fan is reduced, the fault is timely predicted and diagnosed, and the purposes of saving the maintenance cost and reducing the rejection rate of the industrial fan are achieved.
Drawings
Fig. 1 is a schematic flow chart of an embodiment of a fault prediction and diagnosis method based on an industrial fan according to the present invention.
Fig. 2 is a schematic structural diagram of an embodiment of the fault prediction and diagnosis device based on an industrial fan according to the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the 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.
The first embodiment is as follows:
referring to fig. 1, fig. 1 is a method for predicting and diagnosing a fault of an industrial fan according to an embodiment of the present invention, including steps S1 to S4,
and step S1, acquiring the iron scrap content data, the vibration data of the industrial fan and the temperature data of the industrial fan within the preset time in a speed reducer of the industrial fan.
In this embodiment, acquiring the iron content data, the vibration data of the industrial fan, and the temperature data of the industrial fan within the preset time in the reduction gearbox of the industrial fan specifically includes:
iron fillings content data in the time of presetting in the gear box of obtaining industrial fan through lubricating oil iron fillings sensor, acquire through acoustoelectric transducer industrial fan's vibrations data and acquire through temperature sensor industrial fan's temperature data.
Specifically, the lubricating oil scrap iron sensor is mounted on a host machine reduction gearbox of the industrial fan in an oil seal mode. The sensing surface of the acoustoelectric transducer and the sensing surface of the temperature sensor are attached to a host motor of the industrial fan.
The iron chip content (when the gear is abraded, iron chips are generated) in the lubricating oil in the host machine reduction box is detected through the induction part of the lubricating oil iron chip sensor, the iron chip content data are obtained, and the iron chip content data reflect the on-off state of the reduction box of the industrial fan host machine.
And step S2, performing fast Fourier transform on the obtained vibration data and performing spectrum analysis to obtain a first data set.
Specifically, in this embodiment, the obtained vibration data is subjected to fast fourier transform to obtain corresponding spectrum data within a preset time period, and the spectrum data is integrated to obtain a corresponding first data set.
And step S3, comparing the first data set, the scrap iron content data and the temperature data with a preset data set and diagnosing the state of the industrial fan to obtain a diagnosis result.
Specifically, the first data set is compared with the preset data set in real time, and whether the first data set has abnormal wave peaks or abnormal frequencies is judged; when the abnormal wave peak does not appear in the first data set, confirming no fault; when the abnormal wave crest appears in the first data set, determining a corresponding fault type according to the type of the abnormal wave crest; the computer can obtain corresponding results according to the fault types (such as bearing wear, insufficient lubrication, abnormal fan blade dynamic balance and the like) represented by the frequency domain in the preset data, and the fault occurrence probability is calculated according to the comparison of the peak value of the frequency wave and the value in the preset corresponding fault tolerance table.
And comparing the scrap iron content data, the temperature data and the preset data set in real time, and obtaining the temperature state of the industrial fan and the on-off state of a reduction gearbox of the industrial fan according to a comparison result.
When a wheel in a reduction gearbox of the industrial fan is worn, scrap iron can enter lubricating oil of the reduction gearbox, a lubricating oil scrap iron sensor is conducted, and a computer can directly judge that the fault type of the signal is gear wear. Correspondingly, the temperature value acquired by the temperature sensor exceeds the preset highest normal temperature, and the computer judges the fault type to be overheating.
Step S4, sending the first data set and the diagnosis result to a WIFI serial server, so that the WIFI serial server sends the first data set and the diagnosis result to a central control information system.
Meanwhile, in this embodiment, after the fault prediction and diagnosis method obtains the diagnosis result, the fault prediction and diagnosis method further sends heartbeat instructions to the WIFI serial server at intervals of a preset time, so that the WIFI serial server sends heartbeat packets to the central control information system at intervals of the first preset time.
Correspondingly, referring to fig. 2, an embodiment of the present invention further provides a fault predicting and diagnosing apparatus for an industrial fan, including a signal acquisition and analysis system 101 and a central control information system 102; the signal acquisition and analysis system comprises a lubricating oil scrap iron sensor 1011, an acoustoelectric transducer sensor 1012, a temperature sensor 1013, an embedded computer 1014 and a WIFI serial port server 1015;
the lubricating oil scrap iron sensor 1011 is used for acquiring scrap iron content data in a preset time in a reduction gearbox of an industrial fan and sending the scrap iron content data to the embedded computer 1014;
the sound-electricity transducer sensor 1012 is used for acquiring vibration data of the industrial fan in real time and sending the vibration data to the embedded computer 1014;
the temperature sensor 1013 is configured to obtain temperature data of the industrial fan in real time and send the temperature data to the embedded computer 1014;
the embedded computer 1014 is configured to perform fast fourier transform on the acquired vibration data and perform spectrum analysis to obtain a first data set; comparing the first data set, the scrap iron content data and the temperature data with a preset data set and diagnosing the state of the industrial fan to obtain a diagnosis result; sending the first data set and the diagnosis result to the WIFI serial server 1015, and sending a heartbeat instruction to the WIFI serial server 1015 at preset time intervals; the embedded computer 1014 of the present embodiment is a microcomputer circuit having an autonomous learning function.
The WIFI serial server 1015 is configured to send the first data set and the diagnosis result to the central control information system 102, and send a heartbeat packet to the central control information system every the first preset time.
Further, the central control information system comprises a tower server, a display, a keyboard, a mouse and a wireless switch; wherein the content of the first and second substances,
the wireless switch is used for providing network access for the signal acquisition and analysis system;
the tower server is used for storing the first data set into a database; and installing corresponding intelligent management software.
The display is used for displaying information of the industrial fan;
the keyboard and the mouse are used for information interaction with an administrator. The administrator can inquire the information of all the industrial fans through the human-computer interface of the display and can access the Web data information access interface at the same time.
Further, the display is used for displaying information of the industrial fan for an administrator to access, and specifically includes: the display is used for displaying the first data set, the diagnosis result, distribution information of the industrial fans in workshop buildings, running states, running time, real-time health conditions, historical maintenance records and next maintenance time. The administrator can also use the same network office computer to log in the Web interface of the central control information system 102 to inquire about the above information.
The fault predicting and diagnosing device is simple to install, high in universality and low in input cost, the running state of the device can be detected without manually ascending to reach the position of the host, the running of the industrial fan is not required to be stopped during detection, the device is not required to wait for stopping or cross-working with production, all industrial fans in the district can not be continuously detected simply, the detection flow is simplified, and human resources and material resources are saved.
Compared with the prior art, the embodiment of the invention has the following beneficial effects:
the embodiment of the invention provides a method and a device for predicting and diagnosing faults of an industrial fan, wherein the method comprises the following steps: acquiring industrial fan data; carrying out fast Fourier transform on the obtained vibration data and carrying out spectrum analysis to obtain a first data set; comparing and diagnosing by combining a preset data set according to the first data set, the temperature data of the industrial fan and the scrap iron content data to obtain a diagnosis result; and sending the diagnosis result of the first data set to a WIFI serial server so that the WIFI serial server sends the first data set and the diagnosis result to a central control information system. Compared with the prior art, the method can realize real-time detection in the operation process of the industrial fan; the obtained data comprise scrap iron content data, vibration data and temperature data, and the method is comprehensive, so that maintenance personnel can know the working state of the industrial fan, the time consumed by the maintenance personnel in diagnosing the industrial fan is reduced, the fault is timely predicted and diagnosed, and the purposes of saving the maintenance cost and reducing the rejection rate of the industrial fan are achieved.
The above-mentioned embodiments are provided to further explain the objects, technical solutions and advantages of the present invention in detail, and it should be understood that the above-mentioned embodiments are only examples of the present invention and are not intended to limit the scope of the present invention. It should be understood that any modifications, equivalents, improvements and the like, which come within the spirit and principle of the invention, may occur to those skilled in the art and are intended to be included within the scope of the invention.
Claims (10)
1. A method for diagnosing a fault of an industrial fan, comprising:
acquiring scrap iron content data, vibration data of the industrial fan and temperature data of the industrial fan within preset time in a speed reducer of the industrial fan;
carrying out fast Fourier transform on the obtained vibration data and carrying out frequency spectrum analysis to obtain a first data set;
comparing the first data set, the scrap iron content data and the temperature data with a preset data set and diagnosing the state of the industrial fan to obtain a diagnosis result;
and sending the first data set and the diagnosis result to a WIFI serial server so that the WIFI serial server sends the first data set and the diagnosis result to a central control information system.
2. The method according to claim 1, wherein the obtained vibration data is subjected to fast fourier transform and spectral analysis to obtain a first data set, specifically:
and carrying out fast Fourier transform on the acquired vibration data to obtain corresponding frequency spectrum data in a preset time period, and integrating the frequency spectrum data to obtain a corresponding first data set.
3. The method for diagnosing the failure of the industrial fan according to claim 1, wherein the diagnosis result is obtained by comparing the first data set, the scrap iron content data and the temperature data with a preset data set and diagnosing the state of the industrial fan, and specifically comprises:
comparing the first data set with the preset data set in real time, and judging whether the first data set has abnormal wave crests;
when the abnormal wave peak does not appear in the first data set, confirming no fault; when the abnormal wave crest appears in the first data set, determining a corresponding fault type according to the type of the abnormal wave crest;
and comparing the scrap iron content data, the temperature data and the preset data set in real time, and obtaining the temperature state of the industrial fan and the on-off state of a reduction gearbox of the industrial fan according to a comparison result.
4. The method for diagnosing the failure of the industrial fan according to claim 1, wherein the obtaining of the data of the content of iron filings, the vibration data of the industrial fan and the temperature data of the industrial fan within the preset time in the reduction gear box of the industrial fan comprises:
iron fillings content data in the time of presetting in the gear box of obtaining industrial fan through lubricating oil iron fillings sensor, acquire through acoustoelectric transducer industrial fan's vibrations data and acquire through temperature sensor industrial fan's temperature data.
5. The method for diagnosing the failure of the industrial fan according to claim 4, wherein the step of acquiring the scrap iron content data of the industrial fan in the reduction gearbox within the preset time through the scrap iron sensor comprises the following specific steps:
detecting the scrap iron content in the reduction gearbox within a preset time through the induction part of the lubricating oil scrap iron sensor to obtain scrap iron content data; the lubricating oil scrap iron sensor is arranged on a host machine reduction gearbox of the industrial fan in an oil seal mode.
6. The method as claimed in claim 4, wherein the sensing surface of the acoustoelectric transducer and the sensing surface of the temperature sensor are both attached to a main motor of the industrial fan.
7. The method as claimed in claim 1, further comprising, after said obtaining the diagnosis result: sending heartbeat instructions to the WIFI serial server every other first preset time so that the WIFI serial server sends heartbeat packets to the central control information system every other first preset time.
8. The fault predicting and diagnosing device for the industrial fan is characterized by comprising a signal acquisition and analysis system and a central control information system; the signal acquisition and analysis system comprises a lubricating oil scrap iron sensor, an acoustoelectric transducer sensor, a temperature sensor, an embedded computer and a WIFI serial port server;
the lubricating oil scrap iron sensor is used for acquiring scrap iron content data in a preset time in a speed reducer of the industrial fan and sending the scrap iron content data to the embedded computer;
the sound-electricity transducer sensor is used for acquiring vibration data of the industrial fan in real time and sending the vibration data to the embedded computer;
the temperature sensor is used for acquiring temperature data of the industrial fan in real time and sending the temperature data to the embedded computer;
the embedded computer is used for performing fast Fourier transform on the obtained vibration data and performing spectrum analysis to obtain a first data set; comparing the first data set, the scrap iron content data and the temperature data with a preset data set and diagnosing the state of the industrial fan to obtain a diagnosis result; sending the first data set and the diagnosis result to the WIFI serial server, and sending heartbeat instructions to the WIFI serial server at preset time intervals;
the WIFI serial port server is used for sending the first data set and the diagnosis result to a central control information system, and sending heartbeat packets to the central control information system at intervals of the first preset time.
9. The apparatus of claim 8, wherein the central control information system comprises a tower server, a display, a keyboard, a mouse, and a wireless switch; wherein the content of the first and second substances,
the wireless switch is used for providing network access for the signal acquisition and analysis system;
the tower server is used for storing the first data set into a database;
the display is used for displaying information of the industrial fan;
the keyboard and the mouse are used for information interaction with an administrator.
10. The apparatus according to claim 9, wherein the display is configured to display information of the industrial fan, specifically: the display is used for displaying the first data set, the diagnosis result, distribution information of the industrial fans in workshop buildings, running states, running time, real-time health conditions, historical maintenance records and next maintenance time.
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| CN202111435878.4A CN114215779A (en) | 2021-11-29 | 2021-11-29 | Fault predicting and diagnosing method and device for industrial fan |
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