CN114895619A - Drying machine and fault self-diagnosis system and control method thereof - Google Patents
Drying machine and fault self-diagnosis system and control method thereof Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 43
- 238000004092 self-diagnosis Methods 0.000 title claims abstract description 23
- 238000001035 drying Methods 0.000 title description 4
- 238000003745 diagnosis Methods 0.000 claims abstract description 27
- 238000010438 heat treatment Methods 0.000 claims abstract description 10
- 238000007405 data analysis Methods 0.000 claims abstract description 5
- 238000012423 maintenance Methods 0.000 claims description 25
- 238000009423 ventilation Methods 0.000 claims description 18
- 238000012360 testing method Methods 0.000 claims description 13
- 239000002274 desiccant Substances 0.000 claims description 8
- 238000004590 computer program Methods 0.000 claims description 6
- 238000004891 communication Methods 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 238000012163 sequencing technique Methods 0.000 claims description 3
- 238000007619 statistical method Methods 0.000 claims description 3
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- 238000001514 detection method Methods 0.000 abstract description 7
- 230000001939 inductive effect Effects 0.000 description 6
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/005—Testing of complete machines, e.g. washing-machines or mobile phones
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/008—Subject matter not provided for in other groups of this subclass by doing functionality tests
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/11—Plc I-O input output
- G05B2219/1103—Special, intelligent I-O processor, also plc can only access via processor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The invention provides a dryer and a fault self-diagnosis system and a control method thereof, wherein the dryer comprises a cylinder group, an assembly reversing valve, a heating unit and a control unit; the fault self-diagnosis system comprises a PLC (programmable logic controller) core controller, four sets of cylinder sensors, eight pressure switches, a valve head controller, a touch screen and a database; when the dryer is switched to a working state, the diagnosis system diagnoses the fault position and counts the fault occurrence frequency; completing big data analysis and mastering the position with the highest fault frequency in the current state; and when fault diagnosis is performed each time, the detection sequence can be flexibly adjusted according to the current latest state of the equipment, so that the fault diagnosis time is further shortened, and the fault diagnosis efficiency is improved.
Description
Technical Field
The invention belongs to the technical field of air dryers, and particularly relates to a dryer fault self-diagnosis method.
Background
The air dryer is widely applied in the industrial field, and the air dryer is used for providing dry compressed air for other test equipment to ensure the normal operation of the test equipment. The main body of the automatic reversing valve comprises hardware such as a control unit, a heating unit, a switching valve assembly, a cylinder and the like, wherein the reversing valve assembly comprises 4 independent reversing valves, wherein the reversing valve 1 and the reversing valve 4 form a group, and the reversing valve 2 and the reversing valve 3 form a group. Similarly, of the four cylinders, the cylinder 1 and the cylinder 4 are grouped, and the cylinder 2 and the cylinder 3 are grouped. The heating unit is used for heating the drying agents in the cavity A and the cavity B and removing moisture in the drying agents. The control unit is mainly used for providing 24V voltage for a valve head controller in the reversing valve assembly and controlling each reversing valve to act so as to change the motion state of each cylinder, as shown in figure 1.
The failure moment of the dryer is concentrated on the moment of switching the process A and the process B, namely the process of switching the cylinder from open to closed, and the problems are mainly concentrated on three parts of a control unit, the cylinder and a reversing valve.
According to the existing fault detection method for the mesh-belt type microwave dryer, a high-voltage test rod is configured on a universal meter through a self-made high-voltage test rod and a self-made capacitance test wire in combination with a pincer-shaped ammeter, and the mesh-belt type microwave dryer is tested and checked. The scheme relies on testing hardware such as a universal meter, a high-voltage testing rod and the like to detect and eliminate faults. In the detection process, personnel are required to operate hardware such as a universal meter on site, result analysis is carried out manually, and the scheme is not flexible enough, single in detection means and low in detection efficiency.
Disclosure of Invention
Based on the problems, the invention provides a dryer and a fault self-diagnosis system and a control method thereof, and aims to solve the problems that the dryer has low fault diagnosis efficiency and long time, and the equipment mobility is influenced.
The invention is realized by the following technical scheme:
a dryer:
the dryer comprises a cylinder group, an assembly reversing valve, a heating unit and a control unit;
the cylinder groups include four identical cylinders, cylinder 1, cylinder 2, cylinder 3, and cylinder 4; cylinders 1 to 4 correspond to 1 to 4 doors, respectively;
the reversing valve assembly comprises four identical reversing valves, namely a reversing valve 1, a reversing valve 2, a reversing valve 3 and a reversing valve 4; the reversing valve 1 is connected with the cylinder 1 through outlets of 1 path and 2 paths, the reversing valve 2 is connected with the cylinder 2 through outlets of 3 paths and 4 paths, the reversing valve 3 is connected with the cylinder 3 through outlets of 5 paths and 6 paths, and the reversing valve 4 is connected with the cylinder 4 through outlets of 7 paths and 8 paths;
the heating unit comprises a cavity A and a cavity B; the cavity A is connected with the cylinder 1 through a door 1 and is connected with the cylinder 3 through a door 3; the cavity B is connected with the cylinder 2 through a door 2 and is connected with the cylinder 4 through a door 4;
the cavity A sends the dried gas into a test room through a one-way valve 1, the cavity B sends the dried gas into the test room through a one-way valve 2, and a two-way pressure valve is arranged between the one-way valve 1 and the one-way valve 2;
and the control unit controls the on-off of each reversing valve in the reversing valve assembly.
Further, the dryer has two working states, namely an A state and a B state;
the A state is as follows: when the reversing valve 1 and the reversing valve 4 are electrified, the air flows through the 1 path, the air flows through the 2 paths, the air flows through the 7 paths and the air flows through the 8 paths, at the moment, the piston in the cylinder 1 moves leftwards under the action of gas pressure, and the 1 door is opened; the piston in the cylinder 4 moves leftwards under the action of gas pressure, and the 4 doors are opened; gas enters through the door 1, most of the gas enters the laboratory through the one-way valve 1 after passing through the cavity A, a small amount of gas enters the cavity B through the two-way pressure valve, and humid gas generated after the drying agent is heated in the cavity B is discharged through the door 4, and in the process, the door 2 and the door 3 are in a closed state;
the B state is as follows: when the reversing valve 2 and the reversing valve 3 are powered on, 3 paths of ventilation are conducted, 4 paths of non-ventilation are conducted, 5 paths of ventilation are conducted, and 6 paths of non-ventilation are conducted, and at the moment, a piston rod in the cylinder 2 moves leftwards under the action of gas pressure, and the door 2 is opened; the piston rod in the cylinder 3 moves to the left under the action of gas pressure, and the 3 doors are opened. Gas enters through the door 2, after passing through the cavity B, most of gas enters the laboratory through the one-way valve 2, a small amount of gas enters the cavity A through the two-way pressure valve, moist gas generated after the desiccant is heated in the cavity A is discharged through the door 3, and in the process, the door 1 and the door 4 are in a closed state.
A fault self-diagnosis system applied to the dryer:
the fault self-diagnosis system comprises a PLC core controller, four sets of cylinder sensors, eight pressure switches and a valve head controller;
the method comprises the steps that a set of cylinder sensors are respectively installed on cylinders 1 to 4, each cylinder sensor comprises a magnetic ring installed on a cylinder piston rod and an inductive switch installed on the outer surface of each cylinder, when the magnetic ring moving along with the piston rod moves to the inductive switch, the inductive switches are magnetized and closed to generate switching value signals, and the switching value signals are transmitted to a PLC (programmable logic controller) core controller and used for detecting the action condition of a piston in each cylinder;
the method comprises the following steps that a pressure switch is arranged at each reversing valve outlet, namely 1-8 paths, when gas passes through the pressure switch, the pressure switch outputs a switching value signal, and the switching value signal is transmitted to a PLC (programmable logic controller) core controller and is used for detecting whether compressed air passes through the corresponding outlet of the reversing valve normally or not;
the reversing valve assembly comprises a valve head controller for controlling the reversing valve to act so that two outlets of the reversing valve alternately output gas; the control unit provides 24V power for the valve head controller to ensure the valve head controller to work normally, and the PLC core controller detects whether the reversing valve assembly receives 24V voltage normally.
Further, the fault self-diagnosis system further comprises a touch screen and a database;
the touch screen and the PLC core controller adopt a network communication mode, the operations of starting and stopping control, parameter setting, data calling and the like of the system are realized through the touch screen, and meanwhile, the PLC controller can display the state parameters of the diagnosis system on the touch screen in real time;
the PLC core controller performs operation processing on the data acquired on site, and stores the data into a database for statistical analysis.
A control method applied to the self-diagnosis system of the dryer comprises the following steps:
the method specifically comprises the following steps:
when the dryer is switched from the working state A to the working state B;
s1, the PLC core controller firstly detects whether the cylinder sensors on the cylinder 1 and the cylinder 4 have switching value signal feedback, if the cylinder sensors do not have switching value signal feedback, the cylinder is judged to be blocked, the system alarms to prompt operation and maintenance personnel to maintain the cylinder, alarm information is displayed on the touch screen, and S5 is executed;
if the cylinder sensor receives the switching value signal feedback, S2 is executed;
s2, the cylinder sensor feeds back a switching value signal normally, namely, a cylinder piston rod acts normally, the cylinder is not blocked, the system detects whether a valve head controller has 24V voltage input, if an analog quantity channel of the PLC core controller does not receive a 24V voltage signal, the system judges that a control unit has a fault, the system alarms and prompts an operation and maintenance worker to prompt the control unit to have the fault, the control panel needs to be maintained or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the analog quantity channel of the PLC core controller normally receives the 24V voltage signal, executing S3;
s3, the PLC core controller can normally receive a 24V voltage signal, namely the control unit has no problem, the pressure difference switch is used for detecting the ventilation conditions of the 1 path of the reversing valve 1 and the 7 paths of the reversing valve 4, if the pressure switches of the two paths are still in a closed state at the moment, the two paths still have gas to pass through, the reversing valve is not normally switched, the core controller can also receive a corresponding switching value signal, the reversing valve is blocked, the system alarms to prompt operation and maintenance personnel that the reversing valve is in fault and needs to be cleaned or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the pressure switches of the 1 path of the reversing valve 1 and the 7 path of the reversing valve 4 are still in the opening state, S4 is executed;
s4, the PLC core controller does not receive the corresponding switching value signal, namely the reversing valve has completed normal switching, the state of the reversing valve is judged to be normal, the system alarms to prompt the operation and maintenance personnel that other parts of the equipment have faults, alarm prompt information is displayed on the touch screen, and S5 is executed;
and S5, finishing diagnosis.
Further, the method specifically comprises the following steps:
when the dryer is switched from the working state B to the working state A;
s1, the PLC core controller firstly detects whether the cylinder sensors on the cylinder 2 and the cylinder 3 have switching value signal feedback, if the cylinder sensors do not have switching value signal feedback, the cylinder is judged to be blocked, the system alarms and prompts operation and maintenance personnel to maintain the cylinder, and alarm information is displayed on the touch screen to execute S5;
if the cylinder sensor receives the switching value signal feedback, executing S2;
s2, the cylinder sensor feeds back a switching value signal normally, namely, a cylinder piston rod acts normally, the cylinder is not blocked, the system detects whether a valve head controller has 24V voltage input, if an analog quantity channel of the PLC core controller does not receive a 24V voltage signal, the system judges that a control unit has a fault, the system alarms and prompts an operation and maintenance worker to prompt the control unit to have the fault, the control panel needs to be maintained or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the analog quantity channel of the PLC core controller normally receives the 24V voltage signal, executing S3;
s3, the PLC core controller can normally receive a 24V voltage signal, namely the control unit has no problem, the pressure difference switch is used for detecting the ventilation conditions of the 3 paths of the reversing valve 2 and the 5 paths of the reversing valve 3, if the pressure switches of the two paths are still in a closed state at the moment, the two paths still have gas to pass through, the reversing valve is not normally switched, the core controller can also receive a corresponding switching value signal, the reversing valve is blocked, the system alarms to prompt operation and maintenance personnel that the reversing valve has faults and needs to be cleaned or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the pressure switches of the 3 ways of the reversing valve 2 and the 5 ways of the reversing valve 3 are still in the opening state, S4 is executed;
s4, the PLC core controller does not receive the corresponding switching value signal, namely the reversing valve has completed normal switching, the state of the reversing valve is judged to be normal, the system alarms to prompt the operation and maintenance personnel that other parts of the equipment have faults, alarm prompt information is displayed on the touch screen, and S5 is executed;
and S5, finishing diagnosis.
Further, the method further comprises:
after the system finishes fault diagnosis each time, storing fault information into a database, automatically counting the frequency of faults occurring at each part in real time, finding out the part with the highest current fault frequency through big data analysis, and sequencing according to the frequency of the faults;
when the dryer breaks down next time, the system automatically and preferentially detects the part with the most frequency of faults, the probability of the part having the faults is higher, if the part does not break down, the part with the middle frequency of faults is detected, and finally the part with the least frequency of faults is detected.
An electronic device comprising a memory storing a computer program and a processor implementing the steps of the above method when executing the computer program.
A computer readable storage medium storing computer instructions which, when executed by a processor, implement the steps of the above-described method.
The invention has the beneficial effects that
The invention carries out real-time state monitoring aiming at fault points frequently appearing in the drying machine, when the drying machine breaks down and stops, the system automatically finishes fault self diagnosis, displays and stores fault information, and assists operation and maintenance personnel to carry out fault treatment. The whole diagnosis process is fully automated, manual intervention is not needed, the fault diagnosis efficiency is greatly improved, the downtime is shortened, and the equipment mobility is improved;
the invention realizes automatic statistics of the fault frequency in the database, completes big data analysis and grasps the position with the highest fault frequency in the current state. And when fault diagnosis is performed each time, the detection sequence can be flexibly adjusted according to the current latest state of the equipment, so that the fault diagnosis time is further shortened, and the fault diagnosis efficiency is improved.
Drawings
FIG. 1 is a schematic diagram of the operation of a dryer system;
FIG. 2 is a schematic diagram of the operation of the fault diagnosis system of the present invention;
fig. 3 is a flowchart of the operation of the fault diagnosis system of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
With reference to fig. 1 to 3.
A dryer:
the dryer comprises a cylinder group, an assembly reversing valve, a heating unit and a control unit;
the cylinder groups include four identical cylinders, cylinder 1, cylinder 2, cylinder 3, and cylinder 4; cylinders 1 to 4 correspond to 1 to 4 doors, respectively;
the reversing valve assembly comprises four identical reversing valves, namely a reversing valve 1, a reversing valve 2, a reversing valve 3 and a reversing valve 4; the reversing valve 1 is connected with the cylinder 1 through outlets of 1 path and 2 paths, the reversing valve 2 is connected with the cylinder 2 through outlets of 3 paths and 4 paths, the reversing valve 3 is connected with the cylinder 3 through outlets of 5 paths and 6 paths, and the reversing valve 4 is connected with the cylinder 4 through outlets of 7 paths and 8 paths;
the heating unit comprises a cavity A and a cavity B; the cavity A is connected with the cylinder 1 through a door 1 and is connected with the cylinder 3 through a door 3; the cavity B is connected with the cylinder 2 through a door 2 and is connected with the cylinder 4 through a door 4;
the cavity A sends the dried gas into a test room through a one-way valve 1, the cavity B sends the dried gas into the test room through a one-way valve 2, and a two-way pressure valve is arranged between the one-way valve 1 and the one-way valve 2;
and the control unit controls the on-off of each reversing valve in the reversing valve assembly.
The dryer has two working states, namely an A state and a B state;
the A state is as follows: when the reversing valve 1 and the reversing valve 4 are electrified, the air flows through the 1 path, the air flows through the 2 paths, the air flows through the 7 paths and the air flows through the 8 paths, at the moment, the piston in the cylinder 1 moves leftwards under the action of gas pressure, and the 1 door is opened; the piston in the cylinder 4 moves leftwards under the action of gas pressure, and the 4 doors are opened; gas enters through the door 1, most of the gas enters the laboratory through the one-way valve 1 after passing through the cavity A, a small amount of gas enters the cavity B through the two-way pressure valve, and humid gas generated after the drying agent is heated in the cavity B is discharged through the door 4, and in the process, the door 2 and the door 3 are in a closed state;
the B state is as follows: when the reversing valve 2 and the reversing valve 3 are powered on, 3 paths of ventilation are conducted, 4 paths of non-ventilation are conducted, 5 paths of ventilation are conducted, and 6 paths of non-ventilation are conducted, and at the moment, a piston rod in the cylinder 2 moves leftwards under the action of gas pressure, and the door 2 is opened; the piston rod in the cylinder 3 moves leftwards under the action of gas pressure, and the 3 doors are opened. Gas enters through the door 2, after passing through the cavity B, most of gas enters the laboratory through the one-way valve 2, a small amount of gas enters the cavity A through the two-way pressure valve, moist gas generated after the desiccant is heated in the cavity A is discharged through the door 3, and in the process, the door 1 and the door 4 are in a closed state.
A fault self-diagnosis system applied to the dryer:
the fault self-diagnosis system comprises a PLC core controller, four sets of cylinder sensors, eight pressure switches and a valve head controller;
the diagnosis system takes a PLC as a core controller, firstly, a set of cylinder sensors are respectively arranged on cylinders 1 to 4, each cylinder sensor comprises a magnetic ring arranged on a piston rod of the cylinder and an inductive switch arranged on the outer surface of the cylinder, when the magnetic ring moving along with the piston rod moves to the inductive switch, the inductive switches are magnetized and closed to generate switching value signals, and the switching value signals are transmitted to the PLC core controller and used for detecting the action condition of a piston in the cylinder;
the method comprises the following steps that a pressure switch is arranged at each reversing valve outlet, namely 1-8 paths, when gas passes through the pressure switch, the pressure switch outputs a switching value signal, and the switching value signal is transmitted to a PLC (programmable logic controller) core controller and is used for detecting whether compressed air passes through the corresponding outlet of the reversing valve normally or not;
the reversing valve assembly comprises a valve head controller for controlling the reversing valve to act so that two outlets of the reversing valve alternately output gas; the control unit provides 24V power for the valve head controller to ensure the valve head controller to work normally, and the PLC core controller detects whether the reversing valve assembly receives 24V voltage normally.
The fault self-diagnosis system also comprises a touch screen and a database;
the touch screen and the PLC core controller adopt a network communication mode, the operations of starting and stopping control, parameter setting, data calling and the like of the system are realized through the touch screen, and meanwhile, the PLC controller can display the state parameters of the diagnosis system on the touch screen in real time;
the PLC core controller performs operation processing on the data acquired on site, and stores the data into a database for big data statistical analysis.
A control method applied to the self-diagnosis system of the dryer comprises the following steps:
the method specifically comprises the following steps:
when the dryer is switched from the working state A to the working state B;
s1, the PLC core controller firstly detects whether the cylinder sensors on the cylinder 1 and the cylinder 4 have switching value signal feedback, if the cylinder sensors do not have switching value signal feedback, the cylinder is judged to be blocked, the system alarms to prompt operation and maintenance personnel to maintain the cylinder, alarm information is displayed on the touch screen, and S5 is executed;
if the cylinder sensor receives the switching value signal feedback, executing S2;
s2, the cylinder sensor feeds back a switching value signal normally, namely, a cylinder piston rod acts normally, the cylinder is not blocked, the system detects whether a valve head controller has 24V voltage input, if an analog quantity channel of the PLC core controller does not receive a 24V voltage signal, the system judges that a control unit has a fault, the system alarms and prompts an operation and maintenance worker to prompt the control unit to have the fault, the control panel needs to be maintained or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the analog quantity channel of the PLC core controller normally receives the 24V voltage signal, executing S3;
s3, the PLC core controller can normally receive a 24V voltage signal, namely, the control unit has no problem, the ventilation conditions of the 1 path of the reversing valve 1 and the 7 paths of the reversing valve 4 are detected through the pressure difference switch, if the pressure switches of the two paths are still in a closed state at the moment, the two paths still have gas to pass through, the reversing valve is not normally switched, the core controller can also receive a corresponding switching value signal, at the moment, the reversing valve is blocked, a system alarms and prompts maintenance personnel that the reversing valve has faults, cleaning or replacement is needed, fault information is displayed on a touch screen, and S5 is executed;
if the pressure switches of the 1 path of the reversing valve 1 and the 7 path of the reversing valve 4 are still in the opening state, S4 is executed;
s4, the PLC core controller does not receive the corresponding switching value signal, namely the reversing valve has completed normal switching, the state of the reversing valve is judged to be normal, the system alarms to prompt the operation and maintenance personnel that other parts of the equipment have faults, alarm prompt information is displayed on the touch screen, and S5 is executed; this situation occurs less often, as shown in fig. 3.
And S5, finishing diagnosis.
The method specifically comprises the following steps:
when the dryer is switched from the working state B to the working state A;
s1, the PLC core controller firstly detects whether the cylinder sensors on the cylinder 2 and the cylinder 3 have switching value signal feedback, if the cylinder sensors do not have switching value signal feedback, the cylinder is judged to be blocked, the system alarms and prompts operation and maintenance personnel to maintain the cylinder, and alarm information is displayed on the touch screen to execute S5;
if the cylinder sensor receives the switching value signal feedback, executing S2;
s2, the cylinder sensor feeds back a switching value signal normally, namely, a cylinder piston rod acts normally, the cylinder is not blocked, the system detects whether a valve head controller has 24V voltage input, if an analog quantity channel of the PLC core controller does not receive a 24V voltage signal, the system judges that a control unit has a fault, the system alarms and prompts an operation and maintenance worker to prompt the control unit to have the fault, the control panel needs to be maintained or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the analog quantity channel of the PLC core controller normally receives the 24V voltage signal, executing S3;
s3, the PLC core controller can normally receive a 24V voltage signal, namely the control unit has no problem, the pressure difference switch is used for detecting the ventilation conditions of the 3 paths of the reversing valve 2 and the 5 paths of the reversing valve 3, if the pressure switches of the two paths are still in a closed state at the moment, the two paths still have gas to pass through, the reversing valve is not normally switched, the core controller can also receive a corresponding switching value signal, the reversing valve is blocked, the system alarms to prompt operation and maintenance personnel that the reversing valve has faults and needs to be cleaned or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the pressure switches of the 3 ways of the reversing valve 2 and the 5 ways of the reversing valve 3 are still in the opening state, S4 is executed;
s4, the PLC core controller does not receive the corresponding switching value signal, namely the reversing valve has completed normal switching, the state of the reversing valve is judged to be normal, the system alarms to prompt the operation and maintenance personnel that other parts of the equipment have faults, alarm prompt information is displayed on the touch screen, and S5 is executed; this situation occurs less often, as shown in fig. 3.
And S5, finishing diagnosis.
The method further comprises the following steps:
after the system finishes fault diagnosis each time, storing fault information into a database, automatically counting the frequency of faults occurring at each part in real time, finding out the part with the highest current fault frequency through big data analysis, and sequencing according to the frequency of the faults;
when the next drier breaks down, the system automatically and preferentially detects the part with the most frequent faults, the probability of the part breaking down is higher, if the part does not break down, the part with the middle frequent faults is detected, and finally the part with the least frequent faults is detected.
Meanwhile, the system dynamically adjusts the detection sequence in real time according to the frequency of faults occurring at each part, so that the fault diagnosis time can be further shortened, and the fault diagnosis efficiency is improved
An electronic device comprising a memory storing a computer program and a processor implementing the steps of the above method when executing the computer program.
A computer readable storage medium storing computer instructions which, when executed by a processor, implement the steps of the above-described method.
The dryer and the fault self-diagnosis system and control method thereof proposed by the present invention are introduced in detail, and the principle and embodiments of the present invention are explained, and the above description of the embodiments is only used to help understanding the method and the core idea of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, there may be variations in the specific embodiments and the application scope, and in summary, the content of the present specification should not be construed as a limitation to the present invention.
Claims (9)
1. A kind of drier, its characteristic is:
the dryer comprises a cylinder group, an assembly reversing valve, a heating unit and a control unit;
the cylinder groups include four identical cylinders, cylinder 1, cylinder 2, cylinder 3, and cylinder 4; cylinders 1 to 4 correspond to 1 to 4 doors, respectively;
the reversing valve assembly comprises four identical reversing valves, namely a reversing valve 1, a reversing valve 2, a reversing valve 3 and a reversing valve 4; the reversing valve 1 is connected with the cylinder 1 through outlets of 1 path and 2 paths, the reversing valve 2 is connected with the cylinder 2 through outlets of 3 paths and 4 paths, the reversing valve 3 is connected with the cylinder 3 through outlets of 5 paths and 6 paths, and the reversing valve 4 is connected with the cylinder 4 through outlets of 7 paths and 8 paths;
the heating unit comprises a cavity A and a cavity B; the cavity A is connected with the cylinder 1 through a door 1 and is connected with the cylinder 3 through a door 3; the cavity B is connected with the cylinder 2 through a door 2 and is connected with the cylinder 4 through a door 4;
the cavity A sends the dried gas into a test room through a one-way valve 1, the cavity B sends the dried gas into the test room through a one-way valve 2, and a two-way pressure valve is arranged between the one-way valve 1 and the one-way valve 2;
and the control unit controls the on-off of each reversing valve in the reversing valve assembly.
2. The dryer of claim 1, wherein:
the dryer has two working states, namely an A state and a B state;
the A state is as follows: when the reversing valve 1 and the reversing valve 4 are electrified, the air flows through the 1 path, the air flows through the 2 paths, the air flows through the 7 paths and the air flows through the 8 paths, at the moment, the piston in the cylinder 1 moves leftwards under the action of gas pressure, and the 1 door is opened; the piston in the cylinder 4 moves leftwards under the action of gas pressure, and the 4 doors are opened; gas enters through the door 1, after the gas passes through the cavity A, most of the gas enters the laboratory through the one-way valve 1, a small amount of the gas enters the cavity B through the two-way pressure valve, and moist gas generated after the desiccant is heated in the cavity B is discharged through the door 4, and in the process, the door 2 and the door 3 are in a closed state;
the B state is as follows: when the reversing valve 2 and the reversing valve 3 are powered on, 3 paths of ventilation are conducted, 4 paths of non-ventilation are conducted, 5 paths of ventilation are conducted, and 6 paths of non-ventilation are conducted, and at the moment, a piston rod in the cylinder 2 moves leftwards under the action of gas pressure, and the door 2 is opened; the piston rod in the cylinder 3 moves to the left under the action of gas pressure, and the 3 doors are opened. Gas enters through the door 2, after passing through the cavity B, most of gas enters the laboratory through the one-way valve 2, a small amount of gas enters the cavity A through the two-way pressure valve, moist gas generated after the desiccant is heated in the cavity A is discharged through the door 3, and in the process, the door 1 and the door 4 are in a closed state.
3. A failure self-diagnosis system applied to the dryer of claim 1 or 2, characterized in that:
the fault self-diagnosis system comprises a PLC core controller, four sets of cylinder sensors, eight pressure switches and a valve head controller;
the method comprises the steps that a set of cylinder sensors are respectively arranged on cylinders 1 to 4, each cylinder sensor comprises a magnetic ring arranged on a cylinder piston rod and an induction switch arranged on the outer surface of each cylinder, when the magnetic ring moving along with the piston rod moves to the induction switch, the induction switches are magnetized and closed to generate switching value signals, and the switching value signals are transmitted to a PLC (programmable logic controller) core controller and used for detecting the action condition of a piston in each cylinder;
the method comprises the following steps that a pressure switch is arranged at each reversing valve outlet, namely 1-8 paths, when gas passes through the pressure switch, the pressure switch outputs a switching value signal, and the switching value signal is transmitted to a PLC (programmable logic controller) core controller and is used for detecting whether compressed air passes through the corresponding outlet of the reversing valve normally or not;
the reversing valve assembly comprises a valve head controller which is used for controlling the reversing valve to act so that two outlets of the reversing valve output gas alternately; the control unit provides 24V power for the valve head controller to ensure the valve head controller to work normally, and the PLC core controller detects whether the reversing valve assembly receives 24V voltage normally.
4. The fault self-diagnosis system according to claim 3, characterized in that:
the fault self-diagnosis system also comprises a touch screen and a database;
the touch screen and the PLC core controller adopt a network communication mode, the operations of starting and stopping control, parameter setting, data calling and the like of the system are realized through the touch screen, and meanwhile, the PLC controller can display the state parameters of the diagnosis system on the touch screen in real time;
the PLC core controller performs operation processing on the data acquired on site, and stores the data into a database for statistical analysis.
5. A control method applied to the self-diagnosis system of the dryer of claim 3 or 4, characterized in that:
the method specifically comprises the following steps:
when the dryer is switched from the working state A to the working state B;
s1, the PLC core controller firstly detects whether the cylinder sensors on the cylinder 1 and the cylinder 4 have switching value signal feedback, if the cylinder sensors do not have switching value signal feedback, the cylinder is judged to be blocked, the system alarms to prompt operation and maintenance personnel to maintain the cylinder, alarm information is displayed on the touch screen, and S5 is executed;
if the cylinder sensor receives the switching value signal feedback, executing S2;
s2, the cylinder sensor feeds back a switching value signal normally, namely, a cylinder piston rod acts normally, the cylinder is not blocked, the system detects whether a valve head controller has 24V voltage input, if an analog quantity channel of the PLC core controller does not receive a 24V voltage signal, the system judges that a control unit has a fault, the system alarms and prompts an operation and maintenance worker to prompt the control unit to have the fault, the control panel needs to be maintained or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the analog quantity channel of the PLC core controller normally receives the 24V voltage signal, executing S3;
s3, the PLC core controller can normally receive a 24V voltage signal, namely the control unit has no problem, the pressure difference switch is used for detecting the ventilation conditions of the 1 path of the reversing valve 1 and the 7 paths of the reversing valve 4, if the pressure switches of the two paths are still in a closed state at the moment, the two paths still have gas to pass through, the reversing valve is not normally switched, the core controller can also receive a corresponding switching value signal, the reversing valve is blocked, the system alarms to prompt operation and maintenance personnel that the reversing valve is in fault and needs to be cleaned or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the pressure switches of the 1 path of the reversing valve 1 and the 7 path of the reversing valve 4 are still in the opening state, S4 is executed;
s4, the PLC core controller does not receive the corresponding switching value signal, namely the reversing valve has completed normal switching, the state of the reversing valve is judged to be normal, the system alarms to prompt the operation and maintenance personnel that other parts of the equipment have faults, alarm prompt information is displayed on the touch screen, and S5 is executed;
and S5, finishing diagnosis.
6. The control method of the dryer self-diagnosis system according to claim 5, characterized in that:
the method specifically comprises the following steps:
when the dryer is switched from the working state B to the working state A;
s1, the PLC core controller firstly detects whether the cylinder sensors on the cylinder 2 and the cylinder 3 have switching value signal feedback, if the cylinder sensors do not have switching value signal feedback, the cylinder is judged to be blocked, the system alarms and prompts operation and maintenance personnel to maintain the cylinder, and alarm information is displayed on the touch screen to execute S5;
if the cylinder sensor receives the switching value signal feedback, executing S2;
s2, the cylinder sensor feeds back a switching value signal normally, namely, a cylinder piston rod acts normally, the cylinder is not blocked, the system detects whether a valve head controller has 24V voltage input, if an analog quantity channel of the PLC core controller does not receive a 24V voltage signal, the system judges that a control unit has a fault, the system alarms and prompts an operation and maintenance worker to prompt the control unit to have the fault, the control panel needs to be maintained or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the analog quantity channel of the PLC core controller normally receives the 24V voltage signal, executing S3;
s3, the PLC core controller can normally receive a 24V voltage signal, namely the control unit has no problem, the pressure difference switch is used for detecting the ventilation conditions of the 3 paths of the reversing valve 2 and the 5 paths of the reversing valve 3, if the pressure switches of the two paths are still in a closed state at the moment, the two paths still have gas to pass through, the reversing valve is not normally switched, the core controller can also receive a corresponding switching value signal, the reversing valve is blocked, the system alarms to prompt operation and maintenance personnel that the reversing valve has faults and needs to be cleaned or replaced, fault information is displayed on a touch screen, and S5 is executed;
if the pressure switches of the 3 ways of the reversing valve 2 and the 5 ways of the reversing valve 3 are still in the opening state, S4 is executed;
s4, the PLC core controller does not receive a corresponding switching value signal, namely the reversing valve is normally switched, the reversing valve is judged to be in a normal state, the system alarms to prompt operation and maintenance personnel that other parts of equipment have faults, alarm prompt information is displayed on a touch screen, and S5 is executed;
and S5, finishing diagnosis.
7. The control method of the dryer self-diagnosis system according to claim 6, wherein:
the method further comprises the following steps:
after the system finishes fault diagnosis each time, storing fault information into a database, automatically counting the frequency of faults occurring at each part in real time, finding out the part with the highest current fault frequency through big data analysis, and sequencing according to the frequency of the faults;
when the next drier breaks down, the system automatically and preferentially detects the part with the most frequent faults, the probability of the part breaking down is higher, if the part does not break down, the part with the middle frequent faults is detected, and finally the part with the least frequent faults is detected.
8. An electronic device comprising a memory and a processor, the memory storing a computer program, characterized in that the processor realizes the steps of the method as claimed in claims 5 to 7 when executing the computer program.
9. A computer-readable storage medium storing computer instructions which, when executed by a processor, implement the steps of the method of claims 5 to 7.
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