CN114462825A - Intelligent operation and maintenance system and method for industrial equipment - Google Patents

Abstract

The invention discloses an intelligent operation and maintenance system and method for industrial equipment, belonging to the technical field of industrial informatization; the method comprises the following steps: the point inspection maintenance module is used for electronizing the paper form, generating a point inspection plan and issuing the point inspection plan to the field operation terminal in real time or at regular time; the repair reporting and maintaining module is used for submitting a repair work order to a security personnel when a field worker finds a fault, receiving the repair work order by the security personnel for maintenance, and feeding back a maintenance result to the closed-loop process management of the field worker; the warehouse spare part module is used for managing spare parts and parts in and out of a warehouse and realizing purchase early warning in a warehouse numerical early warning mode; the data analysis module is used for monitoring the point detection result and the implementation result of repair and maintenance, collecting data and analyzing the data to realize data display; the electronic operation instruction module generates an electronic operation instruction through template introduction and schematic diagram insertion; and the report exporting module is used for carrying out classified statistics on the point detection results and exporting the required data by taking a month as a unit.

Description

Intelligent operation and maintenance system and method for industrial equipment

Technical Field

The invention belongs to the technical field of industrial informatization, and particularly relates to an intelligent operation and maintenance system and method for industrial equipment.

Background

Industrial equipment, particularly large-scale production equipment, is essential to normal production processes of enterprises, but due to the high price of the equipment, the enterprises cannot generally afford to purchase spare equipment. Therefore, it is important for an enterprise how to ensure the fault-free operation of the primary equipment. With the improvement of the technological content and the acceleration of the technology upgrade of industrial products, the users are increasingly difficult to master the professional skills of product operation and maintenance. This results in increased operational difficulty and scarcity of professional maintenance personnel.

The demand of the equipment users for specialized operation and maintenance services becomes stronger. With the deep integration of informatization and industrialization, the adoption of a remote mode to develop services is an important development direction of operation and maintenance of industrial equipment. The system realizes remote monitoring on large-scale equipment with wide geographical distribution, mobilizes fault diagnosis and maintenance service resources in a short time, and realizes quick, timely and correct diagnosis and maintenance of a complex system. An effective remote operation and maintenance service system is established, the production loss of a user is reduced to the maximum extent, meanwhile, the working efficiency is improved, and the operation and maintenance cost is reduced.

The development of industrial app is based on an internet technology network, equipment, people and data analysis (three elements of an industrial internet) are connected, intelligent and digital transformation in the industrial field is realized by utilizing big data analysis, energy consumption is reduced, and efficiency is improved. The key technologies of the industrial internet platform comprise: application development and microservice techniques, industrial data modeling and analysis techniques, data management techniques, platform enablement techniques, IaaS techniques, data integration and edge processing techniques. The method can be divided into a ubiquitous sensing technology direction, a full-interconnection manufacturing network technology direction and an intelligent manufacturing cloud service technology direction according to the direction. The ubiquitous sensing technology mainly refers to ubiquitous sensing of equipment and a production process, and solves the technical problems of interference resistance, high real-time performance and low power consumption in industrial application by utilizing a WSN (wireless sensor network) technology of interconnection communication. The WIA-PA (wireless sensor network technology with low speed and low power consumption facing to the ubiquitous perception of the process industry) realizes self-adaptive frequency hopping, a multi-hop high real-time transmission technology and a high-precision synchronization technology on the basis of a physical layer, and increases the reliability of data transmission. The full-interconnection manufacturing network technology realizes the comprehensive interconnection of a factory management network, a control network and a sensing network based on a TCP/IP framework of the Internet, integrates with the Internet and realizes seamless information transmission. The intelligent manufacturing cloud service realizes dynamic self-organization of manufacturing application in a modularization and servitization mode, provides basic services such as data management and modeling, provides core services such as data analysis, simulation and optimization, and supports the development of manufacturing application.

The platform enabling technique has: disaster tolerance characteristic, high-efficiency compression transmission method and light-weight high-strength encryption mechanism. The data management technology supports the big data processing capacity of real-time incremental data and ensures the safety of data integration. The industrial data modeling and analyzing technology is designed for factory/workshop planning, and a layout analysis model is optimized; lean control of production models and processes such as product models, equipment models and business models is realized; the technology of VR, AR and the like is used for realizing the fusion of virtual and reality, and the method can be widely applied to the aspects of practical training, production monitoring, maintenance guidance, intelligent warehousing and the like.

The application of such industrial internet technology may face the following problems:

the production field can not form the management of the whole life cycle, all links are mutually independent, and the information intercommunication effect is low;

secondly, under the influence of a special industrial environment in a factory building, time delay occurs in field data and service transmission;

disclosure of Invention

The invention provides an intelligent operation and maintenance system and method for industrial equipment, aiming at solving the technical problems in the known technology, and forming an industrial internet application mode characterized by interconnection manufacturing, namely an integration mode taking intelligent design, interconnection products and intelligent manufacturing production as elements in order to avoid the defects in the industrial internet technology.

The invention provides an intelligent operation and maintenance system for industrial equipment, which comprises a point inspection maintenance module, a repair maintenance module, a warehouse spare part module, a data analysis module, an electronic operation instruction book module and a report export module; wherein:

the point inspection maintenance module is used for electronizing the paper form, generating a point inspection plan and issuing the point inspection plan to the field operation terminal in real time or at regular time;

the repair reporting and maintaining module is used for submitting a repair work order to a security personnel when a field worker finds a fault, receiving the repair work order by the security personnel for maintenance, and feeding back a maintenance result to closed-loop process management of the field worker;

the warehouse spare part module is used for managing spare parts and parts in and out of a warehouse and realizing purchasing early warning in a warehouse numerical early warning mode;

the data analysis module monitors the point detection result and the implementation result of repair and maintenance, collects data and analyzes the data to realize data display;

the electronic operation instruction module generates an electronic operation instruction through an Excel template import and schematic diagram insertion mode, and exports a pdf format by one key;

and the report exporting module is used for carrying out classified statistics on the point detection results and exporting the required data by taking a month as a unit.

Preferably, the point inspection maintenance module comprises a Pad information terminal or a mobile phone APP, and the content displayed in the point inspection maintenance module comprises a point inspection maintenance plan and a point inspection maintenance history, wherein the point inspection maintenance plan comprises items, equipment, plan starting time, inspection modes and input modes to be inspected; the inspection and maintenance history includes the contents and execution results of the inspection and maintenance plan in each state.

Preferably, the repair and maintenance module includes four aspects of fault repair, rapid work order, repair after order receiving and repair confirmation, and performs fault detail work order repair on the equipment with the fault, generates a repair and repair work order, calls required warehouse spare parts according to the work order details to perform field maintenance, generates a maintenance record after the repair is completed, and feeds the maintenance record back to a work order initiator for auditing.

Preferably, the warehouse spare part module manages the name information, the warehousing list, the ex-warehouse list and the warehousing and ex-warehouse information of the spare parts and the warehouse through an industrial equipment intelligent operation and maintenance system, and sets the in-warehouse quantity of the spare parts simultaneously, so that upper and lower limit early warning and reminding are realized.

Preferably, the data analysis module displays key values in the point inspection and maintenance history on the intelligent operation and maintenance system of the industrial equipment, wherein the key values comprise point inspection parameters, point inspection history, exception details, fault profiles, exception statistics, repair history and incomplete work orders.

Preferably, the electronic operation instruction book module manages the basic information, the operation process content, the inspection process content, the notice, the tool equipment and the material specification of the instruction book through the intelligent operation and maintenance system of the industrial equipment, and sends the basic information, the operation process content, the inspection process content, the notice, the tool equipment and the material specification of the instruction book to the corresponding pad information terminal.

Preferably, the report export module reads the historical data of point inspection and maintenance in the database and exports the historical data by category and monthly classification.

The second objective of the present invention is to provide an intelligent operation and maintenance method for industrial equipment, which includes the following steps:

s1, the security department creates a daily check plan through the check maintenance module and issues the daily check plan to the field operation terminal, and after the field operation terminal user receives the corresponding check plan, the field operation terminal user confirms that the equipment has no fault and can work normally, and then executes the corresponding check task according to the check plan;

s2, when the field operation terminal user executes the daily task, acquiring a relevant operation instruction issued by the electronic operation instruction module for instructing the standardized execution of the spot inspection task, and after the daily task is executed, backfilling the production data and the equipment basic information data into the spot inspection maintenance module;

s3, performing online examination and confirmation on the completed daily point inspection plan, and confirming that the execution result of each task is normal and meets the requirement and then the task passes the verification; the passed data information is synchronously transmitted back to the point inspection and maintenance module and written into a database for storage, and meanwhile, the data is displayed after being integrated and analyzed by the data analysis module;

s4, when the production equipment has a fault, a new repair work order is created in real time, and work order data are uploaded to a repair maintenance module through the field operation terminal;

s5, after receiving the repair work order, the security department acquires the positioning information of the maintenance group personnel in real time through the fault billboard management system, selects the maintenance personnel nearby and sends the repair work order to the corresponding maintenance personnel;

s6, after receiving the maintenance work order, the maintenance group personnel self-evaluates and selects whether to accept the maintenance work order, after accepting the work order, the maintenance group personnel represent to start maintenance, and in the maintenance process, the maintenance personnel can basically describe the fault information in the form of characters, voice or pictures and videos; calling spare part library information and selecting the required spare parts; meanwhile, the maintenance workload is evaluated, and corresponding maintenance auxiliary personnel are added according to the idle condition of the personnel;

s7, after the maintenance is finished, the maintenance personnel can record the fault occurrence phenomenon, the root cause and the solution of the fault occurrence, and the root cause and the solution are used for constructing a fault knowledge base system; meanwhile, the working content and the working duration of each maintenance worker need to be input, so that the working content and the working efficiency of different workers can be counted, and the production link can be improved;

s8, after the maintenance is finished, the maintenance work order is synchronized to the point inspection and maintenance module, the quality of the production field operation personnel is required to be confirmed, whether the fault is repaired is confirmed, and after the normal operation of the equipment is confirmed, the operation and maintenance process is finished;

s9, uploading the recorded repair and maintenance information and data to a repair and maintenance module, writing the information and data into a database for storage, and displaying the information and data after data integration and analysis by a data analysis module;

s10, the report exporting module performs statistical analysis on the written data to form a fault operation and maintenance knowledge base; and displaying the fault time length, the fault times and the fault equipment information. The invention has the advantages and positive effects that:

analysis from a performance perspective: the intelligent operation and maintenance system for the industrial equipment integrates the mobile internet technology and the internet of things technology, solves the problem of platform decentralized management of data flow and control flow, is unified to the same platform, strengthens the internal relation between data and management, records a form which is difficult to be managed in a standardized way into the intelligent operation and maintenance system for the industrial equipment, and performs operations such as updating, modifying, newly adding and the like on unified management data through a system background; the intelligent operation and maintenance system of the industrial equipment improves the speed of data transmission between services and reduces the occurrence of transmission delay through database optimization; the intelligent operation and maintenance system of the industrial equipment analyzes a large amount of data of the production data and the operation and maintenance data collected by the access terminal, summarizes the data to form an operation and maintenance knowledge base system, and becomes an instructive basis for enterprise operation and maintenance decision; the intelligent operation and maintenance system of the industrial equipment introduces a data tag and a tracking mechanism, so that the traceability of data is improved, and the tracing breadth and depth are increased.

1-3 months after the system is imported, the intelligent operation and maintenance system of the industrial equipment implements a data-first principle, and the operation and maintenance data platformization is realized by importing actual production and manufacturing data and performing three-dimensional operation and maintenance monitoring system; 4-6 months after the system is introduced, the system can realize abnormal data alarm by analyzing whether the production data collected by the access terminal exceeds the set value of the abnormal condition, further analyze the reason of the fault occurrence and form an early warning mechanism by long-time data accumulation; after the system is imported, active intelligent operation and maintenance can be realized 6-12 months later, the system can provide support for decision making of a management layer, and the system can actively push operation and maintenance service information through data monitoring planning, comprehensive operation and maintenance management, fault tracking and the like.

From a customer benefit perspective analysis: the intelligent operation and maintenance system for the industrial equipment solves the following six pain points of the customer:

1. the efficiency is low:

the paper point inspection form is low in efficiency of making, updating, printing and distributing.

2. In the form of:

manual recording, the process cannot be traced, and the process flows into a form; the hidden production trouble cannot be effectively checked.

3. Data cannot be counted:

manually recording, and forming a report form by data statistics.

4. Data trend cannot be backtracked:

and the data trend cannot be backtracked for a long period when production problems occur.

5. Difficult to store:

paper documents are difficult to keep.

6. Difficulty in training:

the content does not form a knowledge base, and the training of new people is difficult.

Analyzing from the aspect of technical characteristics: the easy-maintenance equipment security system integrates factory field operation scenes of production enterprises, carries out product standardization development and realizes the following characteristics:

data visualization

The human brain processes visual information much more easily than written information. Using charts to summarize complex data ensures that relationships are understood faster than in chaotic reports or spreadsheets.

The system integrates data visualization, complex and obscure data are displayed to workers in forms of simple and intuitive diagrams, reports and the like through a data visualization technology, and key information and important data are clear at a glance.

Flow normalization

The system standardizes the production operation flow, removes redundant links, improves the execution efficiency of the business flow, avoids human errors and avoids non-standardized business.

Service digitization

The system realizes digital conversion of services, saves the cost of traditional paper materials, can introduce multimedia information forms such as photos, voice, video and the like, improves the expressive force of work orders compared with text description, and enables operation and maintenance personnel to know the field situation more intuitively and efficiently. The content of the knowledge base can be more diversified.

Wealth of knowledge

The operation and maintenance data is managed systematically, so that the operation and maintenance data is convenient to retrieve, the management cost of the data is saved, and a knowledge base is formed based on the operation and maintenance work order, the equipment information and other data to guide and train the operation and maintenance service skills of non-professional technicians.

Functional servitization

The device operation and maintenance function is constructed in a micro-service mode, and the reuse of the function is facilitated. In addition, other functional services can be conveniently combined to solve more complex services and problems.

From the perspective of social benefit:

(1) forming an industrial knowledge base:

along with the expansion of customers and the evolution of projects, the acquisition and accumulation of real-time and non-real-time data streams of industrial equipment are gradually realized, an equipment operation and maintenance knowledge base is formed through multi-dimensional data analysis, value-added services are provided for the customers, the operation and maintenance response time is shortened, and the operation and maintenance quality is improved.

(2) And (3) constructing an industrial standard:

through the accumulation of mass data, an industrial data standard is formulated and perfected, and the rapid development of the field of industrial Internet of things is promoted.

(3) Forming a standardized industry solution:

by means of the introduction of customer requirements, real pain points of enterprise customers in actual production and life are deeply dug, and an industry universal solution with stronger applicability is gradually formed.

(4) The energy conservation and environmental protection are realized:

the system stores data by an electronic means, and greatly reduces resource waste caused by paper waste.

From the perspective of cost, aiming at the problem of low efficiency of the existing business, the method realizes that enterprises and field operating personnel can be directly connected to equipment users, systematic, normalized and flow design is carried out on production operation, and unnecessary links of intervening personnel are omitted.

From the perspective of communication efficiency, aiming at the situations that the problem description is unclear and needs to be communicated repeatedly, the system increases the display of multimedia elements on the basis of the text description, for example, after-sales services such as equipment failure shooting uploading, equipment running state video acquisition and remote video assistance enable the problem description form to be diversified, and operation and maintenance personnel can know and master the failure situation more intuitively.

From the perspective of field operation, aiming at the condition of lacking the capability of information comprehensive judgment such as understanding of field operation condition, distribution of personnel configuration information and the like, the system collects, perfects and systematically manages information data of fault work orders, routing inspection/point inspection plans and repair maintenance personnel, and the intelligent dispatching is realized through the comprehensive judgment of various information, so that the operation efficiency is improved;

from the perspective of system superiority, the system forms an operation and maintenance knowledge base according to the contents of past routing inspection/point inspection plans, reported maintenance histories, equipment data and the like, reduces part of operation and maintenance thresholds, and enables non-professional personnel, customer service and even customers to complete simple and common fault problems under the guidance of the knowledge base. Through the accumulation of the knowledge base and the actual operation and maintenance monitoring data, technology in the industry can be formed to guide productization output, and the conversion of knowledge to wealth is completed.

From the perspective of functional design, the system adopts functional modular design, has good expandability, focuses on the future of enterprises, and facilitates the introduction of new business functions. And sufficient preparation is provided for advanced technologies such as machine learning and big data analysis.

Drawings

FIG. 1 is a system block diagram of a preferred embodiment of the present invention;

FIG. 2 is a flow chart of a point inspection and maintenance module in accordance with a preferred embodiment of the present invention;

FIG. 3 is a flow chart of a repair and maintenance module in accordance with a preferred embodiment of the present invention;

FIG. 4 is a flow diagram of a warehouse spare module in a preferred embodiment of the present invention;

FIG. 5 is a flow chart of the electronic work instruction module in the preferred embodiment of the present invention.

Detailed Description

In order to further understand the contents, features and effects of the present invention, the following embodiments are illustrated and described in detail with reference to the accompanying drawings:

the technical scheme of the invention is as follows:

an intelligent operation and maintenance system for industrial equipment, comprising:

firstly, a spot inspection maintenance module: the paper board point inspection table is electronized to form a point inspection plan, so that repeated input can be reduced, time and efficiency are saved, and meanwhile, the data input system can be maintained for a long time in the later stage of background storage, and loss prevention is achieved. The spot inspection plan input by the system background can be issued to corresponding operating equipment by taking equipment and users as units, a field user can perform spot inspection operation before equipment production according to information input in advance, original complex and disordered data is normalized to form an electronic chart, and historical data can be checked by one key; meanwhile, key node data are photographed and evidence is obtained, and the real-time performance and effectiveness of photographing can be guaranteed by adding the watermark to the photo. The executed plan can be fed back to the background management end, so that a management layer user can conveniently master the field operation progress and the implementation condition in an office, the historical data supports on-line style export, and template customization can be carried out according to the requirements of customers. In order to realize the closed-loop operation of the operation flow, an online confirmation function is added for the execution of the point inspection plan, and the multi-level confirmation ensures the accuracy of field operation implementation and avoids causing sudden failure and shutdown of equipment. The meaning of regularly maintaining the functional module lies in, through the inspection of regularly patrolling, carry out spot check to equipment key data, through the life of regularly maintaining extension equipment, increase the durability of equipment.

II, a repair maintenance module: the method comprises the steps that a production field worker initiates a fault to-be-maintained work order, a security manager performs worker dispatching according to the type and position of the fault, sends the corresponding work order to operating equipment of the security manager, then the security manager can call the work order to be maintained and performs maintenance, after the maintenance is completed, the work order can be fed back to a field production operator for inspection, the equipment to be confirmed can normally produce, namely, the fault maintenance is completed, and then the process is completely finished. During this period, the security personnel can get management end spare part information, if some spare parts are lacked in the maintenance process, can carry out spare part at any time and take to communicate information to spare part management module, realize the linkage between module and the module.

Thirdly, a warehouse spare part module: all kinds of spare parts required for production and preservation are recorded in a background of a management end, and only periodic maintenance and updating are needed in a later period after the recording is carried out once, so that the time is saved, and the efficiency is high. The inventory management part artificially limits the quantity of different spare parts entering and leaving the warehouse and the quantity of the spare parts in the warehouse, when an alarm line is reached, the system can display different forms, gives the most direct visual feeling to a user, and can quickly position the conditions of the spare parts needing to be purchased and the spare parts with insufficient inventory. The spare parts can automatically form a corresponding unique work order number when entering and leaving the warehouse, and the system keeps traces and records the executors of the corresponding operation, so that the person is responsible.

And fourthly, a data analysis module: the implementation results of the point inspection plans, the execution conditions of regular maintenance and repair are managed and analyzed, the execution states of all the point inspection plans are determined, big data are captured, the point inspection plans are displayed more clearly and visually, and a user can conveniently and quickly obtain required key information. Through the frequency and the failure response time analysis of gathering reporting to repair the maintenance, can help the user to fix a position the trouble condition of each equipment, can make clear the life of equipment through the trouble condition analysis, simultaneously, the response time of trouble also can reflect the operating efficiency of security personnel, through data management and control, can help the enterprise to realize promoting the effect and reducing originally, the management objective of steady production.

And fifthly, an electronic operation instruction book module: the method is used for guiding the execution of the field production operation process and the flow, and refining the process, including the content of work processes, inspection processes, cautions and the like. The execution condition of each process flow and the overall progress of the production operation are determined through the pad information terminal, the production progress of each product can be confirmed at the management end, and then the scheduling and production plan adjustment are carried out. By means of electronization, efficient transfer of field processes is achieved, and field personnel are helped to carry out overall scheduling and production regulation and control.

Sixthly, a report exporting module: the data collected by the point inspection and maintenance module are summarized and analyzed according to monthly, equipment, plan and other subdivision items, an Excel table form is generated and derived, the Excel table form can be used for enterprise asset retention, and meanwhile, the enterprise can conveniently trace process data.

Referring to fig. 1, the present invention utilizes the mobile internet technology to perform comprehensive management on point inspection maintenance, repair and repair, spare part warehouse, and electronic operation instruction book modules in industrial production and manufacturing, and based on the mobile internet technology, the present invention integrates an enterprise management layer, field users, and production equipment into a unified platform, and has the ability to closely cooperate with the existing business system, equipment failure detection system, and the like. The system mainly aims to manage the whole life cycle of production based on the Internet technology and the IoT technology, and improve the transmission speed of factory site information and services, so that efficient and reliable operation of production operation is realized and guaranteed. The system not only solves the problem of business process management of production operation, but also improves the informatization of production and manufacturing to a new step through the technical integration of data visualization, mobile internet elements and the like.

According to the usage scenario of the system, the user and system deployment environments can be divided into the following three types:

A) the field worker: the Pad information terminal can be accessed to perform electronic operation, including point inspection, completion of inspection tasks, historical record checking, graphical display of data and linkage approval activities with a management end.

B) And the management layer user: the system can access a PC management terminal, check information such as the completion condition of the whole operation, the fault occurrence rate and the like, remotely control the field operation condition of a factory, and realize the statistical analysis and management of the operation and maintenance data of the equipment through big data analysis.

C) Software and hardware requirements: the system software can be divided into a PC management end, a Pad application end and a mobile phone APP end.

A PC terminal: browsers that support mainstream in the market, for example: IE browser, Chrome, firefox, Safari browser, etc.

And a Pad end: by applying military-grade three-proofing Android PAD, the service life of the equipment is guaranteed to the maximum extent from the hardware perspective, and the equipment is resistant to falling and collision; from the software perspective, convenient to carry, the functionality is stronger.

The mobile phone APP terminal: and the running of the Android system app is supported.

The overall architecture of the intelligent operation and maintenance system for the industrial equipment can be divided into: access terminal, forwarding layer, control layer, service layer, frame layer, persistent layer and memory management. Wherein:

the access terminal mainly refers to software and hardware applications of the system, and comprises: PC management end, Pad user end and APP. The PC management terminal acquires data such as system users, inspection plans, spare part warehouse information, department information and the like which are input by the users through the browser from the database; the Pad user side uploads the production data, the inspection result, the repair and maintenance work order and other data information input by the user through the Pad to a database for storage; the APP terminal is mainly used for receiving query result data from a database and data such as a routing inspection plan, a spare part warehouse and repair and maintenance information called by the PC terminal, and meanwhile, inputting of production data and the like and creating, executing, feeding back and the like of repair and maintenance work orders can be carried out. After the received data is sent to a control layer through a forwarding layer for authority distribution, service functions of different commands can be identified; the system function is realized through the service layer, the function support is carried out through the framework layer, then the data enters the persistent layer to be stored for a long time, and is written into the memory management layer to be stored in the database and the cloud server, and the whole service flow architecture is realized.

The persistent layer comprises a Content Delivery Network (CDN), the operation and maintenance system ensures the real-time performance of system data by using the CDN, the response speed and the loading speed of the system and a page are improved, and the user experience is greatly improved; the business layer comprises a monitoring center and a business server, a message channel is constructed between the monitoring center and the business server by using WebSocket, and after the business server receives a new task instruction, the new task instruction is transmitted to the data monitoring center in real time through the message channel, so that management end personnel can master the field condition in time and reasonably arrange personnel, plans and equipment materials; the forwarding layer utilizes APNS message pushing to initiate remote RPC calling from the service server to the application layer APNS server, and pushes the message to designated personnel (such as field inspection personnel and point inspection personnel) through the APNS server, so that the relevant personnel can know the plan execution state in time, master the whole operation progress and realize electronic operation;

the interface UI frame layer uses the Android responsive UI frame independently researched and developed by the operation and maintenance system, normal display can be realized on Android equipment with different resolutions, the compatibility with more than 90% of mainstream machine types can be realized, the display problems of stretching, twisting and the like can not be generated, and the problem of Android fragmentation is fully solved.

In order to ensure the safety and reliability of data transmission, the system adopts equipment with high safety level from the aspects of a server, a database and a component to carry out system construction. The Alice cloud server ECS (electronic computer service) has the advantages of high stability, high safety, high availability, expandability and the like, can be quickly integrated with other self-contained components of the Alice cloud, such as Redis, MySQL, SLB and the like, and can reduce the deployment cost and the maintenance cost of an enterprise. The database automatically backs up the full data at regular time, thereby preventing the data from being lost accidentally and ensuring the data safety.

From the system design level:

(r) MD5 encryption of user password

The user password is encrypted by MD5, which is an encryption algorithm with very high security and is widely applied to the fields of file verification, bank password encryption and the like, and because of the irreversibility of the encryption, the possibility of cracking is almost avoided when a random password consisting of more than 10 letters and numbers is used.

② COOKIES encryption

When the system stores COOKIES, the data stored in COOKIES adopts an improved special encryption algorithm which is based on MD5 encryption and adds a random encryption factor. If a non-standard MD5 encryption is used, the data held in the system cookie is not likely to be decrypted. Therefore, it becomes completely impossible for hackers to try to attack the system with fake cookie, ensuring high security of the system user profile.

③ SQL injection protection

In the aspect of SQL injection prevention, the system sets four safety protections:

(1) system level SQL injection prevention detection. The system will go through detecting all the data submitted to the server by GET, POST, cookie, if it is found possible to construct abnormal code that can be injected into SQL, the system will terminate the program running and record the log. This security protection added to the database before it is connected can withstand almost all SQL injections and data submissions that compromise website security before it is connected to the database.

(2) Program level security against SQL injection systems. In the application program, before the SQL query statement is constructed, the system acquires data from the outside, brings the data into the variables assembled into the SQL to carry out security validity verification, and filters the characters which possibly form the injection.

(3) The external submission of the form is prohibited. The system forbids the submission of the form from other domain names except the domain name, and prevents the transmission of the aggressive code from the external jump.

(4) Database operations use stored procedures. All important data operations of the system use a storage process as parameter query, thereby avoiding assembling SQL character strings and ensuring that the system can not play a role even though the system passes the aggressive characters of SQL injection filtering layer by layer.

Authority control system

The system is provided with a strict and effective authority control system, the authority setting system has a plurality of authority configuration contents, different columns can set completely different authorities, and all the authorities are strictly controlled on a plurality of levels.

The multi-protocol access framework design method based on the Laravel development framework adopts the Internet technology, the multi-protocol access framework design is carried out based on the Laravel development framework, multi-protocol access such as MQTT, HTTP and IP is supported, and multi-dimensional three-dimensional alarm is realized by utilizing a plurality of modes such as a platform background, short messages, mails and push pushing. Meanwhile, the platform supports multi-client login, the coverage range is wide, and multi-level user management can be realized. Through long-term platform data storage and analysis, the intelligent inheritable operation and maintenance knowledge base system can be formed by a client, and the establishment of an industry standardization standard is realized. The system integrates a plurality of functional modules such as field operation, security maintenance, equipment management, raw material warehouse, data analysis, electronic operation instruction books and report statistics, and meets the production and manufacturing requirements of rapid and efficient operation in a production field, transparent warehousing and material taking, traceable data analysis and the like.

The field operation module can be divided into three modules of checking project making, point inspection plan execution and regular maintenance, and mainly solves the problem that a customer production field is lack of an information terminal. The inspection project formulation defines project execution requirements and inspection contents, and can be inserted into an electronic operation guide diagram to help a user to quickly position the contents needing point inspection. The inspection project is the minimum unit of the check plan, and a plurality of inspection projects can form a check plan. The paper board point inspection table is electronized to form a point inspection plan, so that repeated input can be reduced, time and efficiency are saved, and meanwhile, the data input system can be maintained for a long time in the later stage of background storage, and loss prevention is achieved. The spot inspection plan input by the system background can be issued to corresponding operating equipment by taking equipment and users as units, a field user can perform spot inspection operation before equipment production according to information input in advance, original complex and disordered data is normalized to form an electronic chart, and historical data can be checked by one key; meanwhile, key node data are photographed and evidence is obtained, and the real-time performance and effectiveness of photographing can be guaranteed by adding the watermark to the photo. The executed plan can be fed back to the background management end, so that a management layer user can conveniently master the field operation progress and the implementation condition in an office, the historical data supports on-line style export, and template customization can be carried out according to the requirements of customers. In order to realize the closed loop operation of the operation process, an online confirmation function is added for the execution of the point inspection plan, the accuracy of field operation implementation is ensured by multi-level confirmation, and sudden failure and shutdown of equipment are avoided. The meaning of regularly maintaining the functional module lies in, through the inspection of regularly patrolling, carry out spot check to equipment key data, through the life of regularly maintaining extension equipment, increase the durability of equipment.

The maintenance module can be divided into two parts of repair reporting and maintenance and spare part calling, so that communication barriers and description deviation between field production personnel and maintenance personnel are solved, the fault occurrence rate is reduced, and the fault response time is prolonged. Meanwhile, the past maintenance records are analyzed in batches to form a systematic knowledge base which can be used as a basis for secondary fault maintenance. The part mainly depends on linkage with field production operation, when field operation personnel find that equipment key data is abnormal and equipment gives an alarm in the spot inspection and production processes, quick response can be realized through linkage of the two modules, and people are responsible. The method comprises the steps that a production field worker initiates a fault to-be-maintained work order, a security manager performs worker dispatching according to the type and position of the fault, sends the corresponding work order to operating equipment of the security manager, then the security manager can call the work order to be maintained and performs maintenance, after the maintenance is completed, the work order can be fed back to a field production operator for inspection, the equipment to be confirmed can normally produce, namely, the fault maintenance is completed, and then the process is completely finished. During this period, the security personnel can get management end spare part information, if some spare parts are lacked in the maintenance process, can carry out spare part at any time and take to communicate information to spare part management module, realize the linkage between module and the module.

The device management module can be divided into two types of production devices and field operation devices (carrying apps), helps enterprises to make clear of field operation devices, facilitates management, and can carry out pretreatment in advance according to depreciation conditions of the devices. The production equipment can be linked with the point inspection plan module, one piece of equipment can correspond to a plurality of point inspection plans, and one point inspection plan can contain a plurality of pieces of production equipment. The field operation equipment is mainly used for realizing functional modules such as point inspection plan execution, regular maintenance, maintenance work order processing, spare part calling and the like.

The raw material warehouse module can be divided into functions of spare part input, inventory management, work order management of entering and leaving warehouse, record storage of entering and leaving warehouse and the like. All kinds of spare parts required for production and preservation can be recorded in a background of a management end, and only periodic maintenance and updating are needed in a later period after the recording is carried out once, so that the time and the efficiency are saved. The inventory management part artificially limits the quantity of different spare parts entering and leaving the warehouse and the quantity of the spare parts in the warehouse, when an alarm line is reached, the system can display different forms, gives the most direct visual feeling to a user, and can quickly position the conditions of the spare parts needing to be purchased and the spare parts with insufficient inventory. The spare parts can automatically form a corresponding unique work order number when entering and leaving the warehouse, and the system keeps traces and records the executors of the corresponding operation, so that the person is responsible.

The data analysis module carries out management and control analysis to the execution condition of point inspection plan and regular maintenance, the implementation achievement of reporting to repair and maintenance, makes clear the execution state of each point inspection plan, snatchs big data, shows more clearly and more directly perceivedly, and convenience of customers obtains required key information fast. Through the frequency and the failure response time analysis of gathering reporting to repair the maintenance, can help the user to fix a position the trouble condition of each equipment, can make clear the life of equipment through the trouble condition analysis, simultaneously, the response time of trouble also can reflect the operating efficiency of security personnel, through data management and control, can help the enterprise to realize promoting the effect and reducing originally, the management objective of steady production.

The electronic operation instruction book module systematically manages the process flow design and procedure execution, integrates and arranges the version of each operation instruction book, the corresponding product and raw material information and other contents, and issues the electronic operation instruction books to corresponding production lines through linkage with the Pad information terminal. A field user can check the electronic operation instruction book of the corresponding product by using the Pad, so that the contents of each process flow link, inspection process, attention matters and the like are clarified, the efficiency of transfer among field operation processes is improved, and the operation error rate is reduced.

The report statistical module is mainly used for sorting and analyzing the data uploaded by the point inspection and maintenance module from the user to form an Excel report and exporting the Excel report, and performing statistical analysis on the implementation result and the confirmation result of each inspection item.

The easy-maintenance equipment preservation system can be applied to various scenes such as boiler, bearing manufacturing, warehouse management, automobile part manufacturing, elevator, water treatment and the like.

The boiler industry:

because boiler equipment size is all great, when daily patrolling and examining and breaking down, hardly overall coverage, with the help of patrolling and examining/some inspection module and the repair and maintenance module of system, can help the enterprise fix a position trouble equipment fast, in time discover the problem, reduce the production problem that the shut down caused.

Manufacturing a bearing:

for production enterprises of fine parts, management of spare parts and inventory of products is vital, unified management of the spare parts and the spare parts can be achieved by the aid of a spare part warehouse module of the system, in addition, the warehouse-in and warehouse-out function module can well record warehouse-in and warehouse-out conditions of the spare parts, and labor cost is saved.

Managing the warehouse:

the large-scale warehouse has various internal product types and is difficult to distinguish in placement positions, and the spare part warehouse module of the system can help the warehouse to manage the complicated product types, so that the phenomena of spare parts, spare part leakage, leakage and the like caused by human reasons are avoided.

Manufacturing automobile parts:

for automobile part manufacturing enterprises, the traditional paper work consumes the internal cost of the enterprises to a great extent, and has the problems of difficult storage, difficult data backtracking and the like. By means of the report counting and inspection/point inspection module of the system, the electronic operation of a factory site can be realized, the operation flow is standardized, the operation time and the fault condition which are high in randomness originally are controlled to be forcibly standardized through the system, and the operation efficiency of personnel is improved.

Fifth, elevator:

the elevator industry pays more attention to periodic point inspection/routing inspection and also has higher requirements on response time after a fault occurs, so that a routing inspection/point inspection module of the system is used,

The repair reporting and maintaining module and the billboard module can help enterprises to conduct electronic operation, repair reporting and maintaining time is saved, fault conditions are displayed on a large screen in real time, and the enterprises can conveniently and integrally master elevator equipment conditions scattered everywhere.

Water treatment:

the problems existing in the water treatment industry mainly lie in the aspects of the thorough degree of sewage treatment, the technical difficulty of up-to-standard discharge, the monitoring strength of sewage treatment and the like. By utilizing a billboard module and a data statistical function of the system and calculating the system, the key field with difficult sewage treatment is determined; by utilizing the billboard module, the achievement of effluent treatment can be clearly and visually displayed, and enterprises can manage more conveniently.

The specific implementation case is as follows:

firstly, a production and manufacturing enterprise:

(1) description of the problem points:

the paper quality inspection table is often missed in the manual inspection process, so that unhealthy running equipment is damaged.

The initial value and the final value are recorded in a point check table mode, and data cannot be traced back for several months when defective products occur.

Training of newly-entered employees is too time-consuming.

The factory area has no data center and no WIFI network environment.

(2) Introduction effect:

importing a point inspection/routing inspection module to electronize the service; and storing for a long time, and taking a picture on a core step according to the service to obtain evidence.

Setting threshold level, viewing data trend graph of any time period in the past in the spot inspection process, alarming and actively maintaining when the threshold is continuously approached. The number of DOWN times is reduced.

The operation instruction book is introduced and compared on site to learn and drill by oneself.

And leasing 1 PAD + leasing the easy-maintenance cloud service to complete the minimum service condition without purchasing hardware assets, establishing a data center and modifying a factory network environment.

Before the system is introduced:

average table spot inspection operation time of 6 production lines: 2 hours;

production sales (daily average): 25000 stations;

consumption of optional products (monthly): 150 sheets

After the system is introduced:

average time of Pad spot inspection operation of 6 production lines: 54 minutes;

production sales (daily average): 30000 a table;

consumption of optional products (monthly): 0 piece of

II, bearing manufacturing enterprises:

(1) description of the problem points:

the paper quality inspection table is frequently missed in the manual quality inspection process, and unhealthy running equipment is damaged.

And the individual point inspection service needs to read the tool information in the NC-PLC so as to be replaced in time.

And (5) producing a team maintenance team, and recording a repair and maintenance bill in a paper mode. The information is not timely and accurately transmitted.

The equipment use condition is opaque, and the ann lamp can not satisfy the demand.

(2) Introduction effect:

importing a point inspection/routing inspection module to electronize the service; and storing for a long time, and taking a picture on a core step according to the service to obtain evidence.

And the imported repair/maintenance module electronizes repair data and maintenance data in the whole process, and is used for enterprise production analysis and audit provided for upstream manufacturers.

And transmitting the equipment data to a PAD end through an industrial control network to record data such as a cutter brand, service time and the like in time.

The introduction billboard module shares and synchronizes the equipment status on site to the monitoring room, office.

Before the system is introduced:

average table spot inspection operation time of 10 production lines: 2.5 hours;

production sales (daily average): 35000 stations;

after the system is introduced:

average time of Pad spot inspection operation of 10 production lines: 45 minutes;

production sales (daily average): 40000 pieces.

Referring to fig. 2 to 5, an intelligent operation and maintenance method for industrial equipment includes:

s1, the security department creates a daily check plan through the check maintenance module and issues the daily check plan to the field operation terminal, and after the field operation terminal user receives the corresponding check plan, the field operation terminal user confirms that the equipment has no fault and can work normally, and then executes the corresponding check task according to the check plan;

s2, when the field operation terminal user executes the daily task, acquiring a relevant operation instruction issued by the electronic operation instruction module for instructing the standardized execution of the spot inspection task, and after the daily task is executed, backfilling the production data and the equipment basic information data into the spot inspection maintenance module;

s3, performing online examination and confirmation on the completed daily point inspection plan, and confirming that the execution result of each task is normal and meets the requirement and then the task passes the verification; the passed data information is synchronously transmitted back to the point inspection and maintenance module and written into a database for storage, and meanwhile, the data is displayed after being integrated and analyzed by the data analysis module;

s4, when the production equipment has a fault, a new repair work order is created in real time, and work order data are uploaded to a repair maintenance module through the field operation terminal;

s5, after receiving the repair work order, the security department acquires the positioning information of the maintenance group personnel in real time through the fault billboard management system, selects the maintenance personnel nearby and sends the repair work order to the corresponding maintenance personnel;

s6, after receiving the maintenance work order, the maintenance group personnel self-evaluates and selects whether to accept the maintenance work order, after accepting the work order, the maintenance group personnel represent to start maintenance, and in the maintenance process, the maintenance personnel can basically describe the fault information in the form of characters, voice or pictures and videos; calling spare part library information and selecting the required spare parts; meanwhile, the maintenance workload is evaluated, and corresponding maintenance auxiliary personnel are added according to the idle condition of the personnel;

s7, after the maintenance is finished, the maintenance personnel can record the fault occurrence phenomenon, the root cause and the solution of the fault occurrence, and the root cause and the solution are used for constructing a fault knowledge base system; meanwhile, the working content and the working duration of each maintenance worker need to be input, so that the working content and the working efficiency of different workers can be counted, and the production link can be improved;

s8, after the maintenance is finished, the maintenance work order is synchronized to the point inspection and maintenance module, the quality of the production field operation personnel is required to be confirmed, whether the fault is repaired is confirmed, and after the normal operation of the equipment is confirmed, the operation and maintenance process is finished;

s9, uploading the recorded repair and maintenance information and data to a repair and maintenance module, writing the information and data into a database for storage, and displaying the information and data after data integration and analysis by a data analysis module;

s10, the report exporting module performs statistical analysis on the written data to form a fault operation and maintenance knowledge base; and displaying the fault time length, the fault times and the fault equipment information. The innovation points of the application are as follows:

optimizing a technical service mode, and constructing a reusable product: the method comprises the steps that the equipment leasing mode is used for realizing the transition from selling customized technical products to selling services; the sales profits of the technical products and the hardware are increased by binding the software and the fixed equipment; through the independent operation and maintenance service, the profit margin and the reliability of the product are improved.

Secondly, realizing lean management in an intelligent and informatization production mode: the utilization rate of the equipment is improved through reasonable division of labor; the lean management and control service based on the public cloud is beneficial to improving the management level of enterprises and enhancing the industrial competitiveness of the enterprises; the independent management and control service based on the private cloud is beneficial to reducing the maintenance cost inside an enterprise and guaranteeing high reliability and high safety of information and data.

And thirdly, realizing dynamic integration of the industrial internet through an intelligent linkage mode: the purchasing, flow management and control, storage, production and maintenance are integrated on an integrated platform, so that the technical and information barriers of the intermediate link are reduced, the operating efficiency is improved, and energy conservation and environmental protection are realized.

And fourthly, realizing end-to-end informatization engineering of the whole value chain of the factory on the basis of a digital means. Through the intelligent linkage mode, the transverse integration of the value network is realized, the real scene condition of the factory is displayed in the form of a virtual factory, and the management is convenient. The vertical integration and the networking construction of a factory are realized by adopting the form of an intelligent factory system.

Based on the technology of the internet of things, field operation data is collected and uploaded to a large-screen billboard, the management process is simplified, the original complex and difficult-to-control fault problems and production problems are clearly and visually displayed in a chart form, a manager is helped to avoid the randomness problems existing in production management, early warning of equipment faults is realized, and early discovery and early solution of the faults are realized.

The above description is only for the preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and all simple modifications, equivalent changes and modifications made to the above embodiment according to the technical spirit of the present invention are within the scope of the technical solution of the present invention.

Claims (8)

1. An intelligent operation and maintenance system for industrial equipment is characterized by comprising a point inspection maintenance module, a repair maintenance module, a warehouse spare part module, a data analysis module, an electronic operation instruction book module and a report export module; wherein:

the point inspection maintenance module is used for electronizing the paper form, generating a point inspection plan and issuing the point inspection plan to the field operation terminal in real time or at regular time;

the repair reporting and maintaining module is used for submitting a repair work order to a security personnel when a field worker finds a fault, receiving the repair work order by the security personnel for maintenance, and feeding back a maintenance result to closed-loop process management of the field worker;

the warehouse spare part module is used for managing spare parts and parts in and out of a warehouse and realizing purchasing early warning in a warehouse numerical early warning mode;

the data analysis module monitors the point detection result and the implementation result of repair and maintenance, collects data and analyzes the data to realize data display;

the electronic operation instruction module generates an electronic operation instruction through an Excel template import and schematic diagram insertion mode, and exports a pdf format by one key;

and the report exporting module is used for carrying out classified statistics on the point detection results and exporting the required data by taking a month as a unit.

2. The intelligent operation and maintenance system for industrial equipment according to claim 1, wherein the inspection and maintenance module comprises a Pad information terminal or a mobile phone APP, and the content displayed in the inspection and maintenance module comprises an inspection and maintenance plan and an inspection and maintenance history, wherein the inspection and maintenance plan comprises items, equipment, plan start time, inspection modes and entry modes to be inspected; the inspection and maintenance history includes the contents and execution results of the inspection and maintenance plan in each state.

3. The intelligent operation and maintenance system for industrial equipment according to claim 1, wherein the repair and maintenance module comprises four aspects of fault repair, quick work order, repair after order receiving and repair after completion confirmation, fault detail work order repair is performed on the equipment with fault, a repair work order is generated, required warehouse spare parts are called according to the work order details for field maintenance, and a maintenance record is generated after the maintenance is completed and is fed back to a work order initiator for auditing.

4. The intelligent operation and maintenance system for industrial equipment as claimed in claim 1, wherein the warehouse spare part module manages the spare parts, the name information of the warehouse, the warehousing list, the ex-warehouse list and the in-warehouse and out-warehouse information through the intelligent operation and maintenance system for industrial equipment, and sets the number of the spare parts in the warehouse to realize upper and lower limit early warning and reminding.

5. The intelligent operation and maintenance system for industrial equipment as claimed in claim 1, wherein the data analysis module displays key values in the inspection and maintenance history, including inspection parameters, inspection history, exception details, fault profile, exception statistics, repair history, and incomplete work orders.

6. The intelligent operation and maintenance system for industrial equipment as claimed in claim 1, wherein the electronic operation instruction book module manages the basic information, operation procedure content, inspection procedure content, notice, tool equipment and material specification of the instruction book through the intelligent operation and maintenance system for industrial equipment, and sends the management result to the corresponding pad information terminal.

7. The intelligent operation and maintenance system for industrial equipment as claimed in claim 6, wherein the report derivation module reads the historical data of point inspection and maintenance in the database and derives the historical data by category and monthly classification.

8. An intelligent operation and maintenance method for industrial equipment is characterized by comprising the following steps:

s1, the security department creates a daily check plan through the check maintenance module and issues the daily check plan to the field operation terminal, and after the field operation terminal user receives the corresponding check plan, the field operation terminal user confirms that the equipment has no fault and can work normally, and then executes the corresponding check task according to the check plan;

s2, when the field operation terminal user executes the daily task, acquiring a relevant operation instruction issued by the electronic operation instruction module for instructing the standardized execution of the spot inspection task, and after the daily task is executed, backfilling the production data and the equipment basic information data into the spot inspection maintenance module;

s3, performing online examination and confirmation on the completed daily point inspection plan, and confirming that the execution result of each task is normal and meets the requirement and then the task passes the verification; the passed data information is synchronously transmitted back to the point inspection and maintenance module and written into a database for storage, and meanwhile, the data is displayed after being integrated and analyzed by the data analysis module;

s4, when the production equipment has a fault, a new repair work order is created in real time, and work order data are uploaded to a repair maintenance module through the field operation terminal;

s5, after receiving the repair work order, the security department acquires the positioning information of the maintenance group personnel in real time through the fault billboard management system, selects the maintenance personnel nearby and sends the repair work order to the corresponding maintenance personnel;

s6, after receiving the maintenance work order, the maintenance group personnel self-evaluates and selects whether to accept the maintenance work order, after accepting the work order, the maintenance group personnel represent to start maintenance, and in the maintenance process, the maintenance personnel can basically describe the fault information in the form of characters, voice or pictures and videos; calling spare part library information and selecting the required spare parts; meanwhile, the maintenance workload is evaluated, and corresponding maintenance auxiliary personnel are added according to the idle condition of the personnel;

s7, after the maintenance is finished, the maintenance personnel can record the fault occurrence phenomenon, the root cause and the solution of the fault occurrence, and the root cause and the solution are used for constructing a fault knowledge base system; meanwhile, the working content and the working duration of each maintenance worker need to be input, so that the working content and the working efficiency of different workers can be counted, and the production link can be improved;

s8, after the maintenance is finished, the maintenance work order is synchronized to the point inspection and maintenance module, the quality of the production field operation personnel is required to be confirmed, whether the fault is repaired is confirmed, and after the normal operation of the equipment is confirmed, the operation and maintenance process is finished;

s9, uploading the recorded repair and maintenance information and data to a repair and maintenance module, writing the information and data into a database for storage, and displaying the information and data after data integration and analysis by a data analysis module;

s10, the report exporting module performs statistical analysis on the written data to form a fault operation and maintenance knowledge base; and displaying the fault time length, the fault times and the fault equipment information.

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