CN114923261A - Central air conditioning unit fault monitoring method and system and central air conditioning unit - Google Patents
Central air conditioning unit fault monitoring method and system and central air conditioning unit Download PDFInfo
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/30—Control or safety arrangements for purposes related to the operation of the system, e.g. for safety or monitoring
- F24F11/32—Responding to malfunctions or emergencies
- F24F11/38—Failure diagnosis
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/50—Control or safety arrangements characterised by user interfaces or communication
- F24F11/52—Indication arrangements, e.g. displays
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/50—Control or safety arrangements characterised by user interfaces or communication
- F24F11/56—Remote control
- F24F11/58—Remote control using Internet communication
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/62—Control or safety arrangements characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
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Abstract
The invention discloses a central air conditioning unit fault monitoring method, a system and a central air conditioning unit; the fault monitoring method for the central air conditioning unit comprises the following steps; establishing an original model; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which are relevant to the unit design parameters; the central air-conditioning unit copies the original model to generate a twin model, and obtains manufacturing parameters in the production and manufacturing process to correct the twin model; acquiring transportation parameters in the transportation process to correct the twin model; acquiring installation parameters in the installation process to correct the twin model; and acquiring operation parameters in the operation process, synchronizing the operation parameters into the twin model, and judging whether a key component failure early warning exists according to the key component failure model in the twin model. According to the invention, the twin model is corrected, so that the accuracy of fault early warning is improved, the maintenance efficiency is improved, and the maintenance cost is reduced.
Description
Technical Field
The invention relates to the technical field of air conditioning, in particular to a central air conditioning unit fault monitoring method and system and a central air conditioning unit.
Background
With the development of physical to virtual mapping technology, digital twin technology that presents physical world states digitally comes into force. At present, the method is developed at a high speed in the fields of logistics, ships, aerospace, automobiles and the like, and helps various enterprises to complete the full life cycle management from product research and development, manufacturing to later operation and maintenance.
The digital twin is to create a virtual model of a physical entity in a digital mode, simulate the behavior of the physical entity in a real environment by means of data, and add or expand new capability to the physical entity through means of virtual-real interaction feedback, data fusion analysis, decision iteration optimization and the like.
The central air conditioning unit is a large high power unit, and the existing monitoring system is an error code arranged in the controller. That is, when a fault occurs in the unit, the controller indicates the cause of the fault by displaying a corresponding error code. When the central air conditioning unit breaks down, the controller can only roughly determine the failure reason from the parameter change in the air conditioning operation process, so the maintenance period is long, the maintenance efficiency is poor, the use of a user is influenced, the user is easily caused with great loss, and the user experience is poor.
And once the central air conditioning unit breaks down, the central air conditioning unit is all destructive, and the damaged part or the part damaged by the fault caused by the damaged part needs to be replaced during maintenance, so that the maintenance cost is increased.
The above information disclosed in this background section is only for enhancement of understanding of the background section of the application and therefore it may contain prior art that does not constitute known technology to those of ordinary skill in the art.
Disclosure of Invention
The invention discloses a method and a system for monitoring faults of a central air conditioning unit and the central air conditioning unit, aiming at the problems pointed out in the background art, wherein the method and the system are used for monitoring the faults of the central air conditioning unit in the whole life cycle and early warning the faults in advance by setting a digital twin model corresponding to the central air conditioning unit, correcting the digital twin model through the actual production, manufacturing, transportation and installation conditions and judging whether the digital twin model has the early warning of the failure of a key component through real-time synchronous operation parameters, so that the maintenance efficiency of the central air conditioning unit is improved, and the maintenance cost of the central air conditioning unit is reduced.
In order to realize the purpose of the invention, the invention is realized by adopting the following technical scheme:
in some embodiments of the present application, a method for monitoring a fault of a central air conditioning unit is provided, which includes:
establishing an original model; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which are relevant to the unit design parameters;
the central air-conditioning unit copies the original model to generate a twin model, and obtains manufacturing parameters in the production and manufacturing process to correct the twin model;
acquiring transportation parameters in the transportation process to correct the twin model;
acquiring installation parameters in the installation process to correct the twin model;
and acquiring operation parameters in the operation process, synchronizing the operation parameters to the twin model, and judging whether a key component failure early warning exists according to the key component failure model in the twin model.
Compared with the prior art, the invention has the advantages and positive effects that:
the central air conditioning unit fault monitoring method corrects the twin model correspondingly arranged on the central air conditioning unit by acquiring the manufacturing parameters with difference, the transportation parameters with difference and the installation parameters with difference in the production and manufacturing processes of the central air conditioning unit, so that the twin model of the central air conditioning unit and the entity machine of the central air conditioning unit have the same unit parameters and running parameters, and the running abrasion statistics generated in the running state under the running parameters in the running process is more accurate; and the failure early warning of the key component judged by the key component failure model related to the unit parameters is more accurate, reliable basis is provided for after-sale failure early warning, the accuracy of the failure early warning is improved, the maintenance period is shortened, the maintenance efficiency is improved, and the maintenance cost is reduced.
In some embodiments of the present application, the raw model is stored in a cloud;
storing a unique manufacturing code corresponding to the central air conditioning unit in the cloud; storing the unique twin model under the manufacturing code;
the original models of the central air conditioning units with different models or capacities correspond to different unit design parameters and different key component failure models; and importing the corresponding original model into the manufacturing code according to the model or the capability of the central air conditioning unit to generate the twin model.
In some embodiments of the present application, the manufacturing code is a code of MES system, which is configured on the central air conditioning unit during the manufacturing process and always follows the full life cycle of the central air conditioning unit; in the production and manufacturing process, code collection is carried out on each station through the MES system, the manufacturing parameters are obtained, and the obtained manufacturing parameters are uploaded to the cloud;
the manufacturing parameters comprise structural connection parameters, structural layout parameters, first refrigerant charging amount, system operation high/low pressure, air tightness and electrical safety parameters.
In some embodiments of the present application, a vibration coefficient is set, which is obtained according to an average value of comprehensive simulation of various road conditions; the vibration coefficient is greater than the average value;
acquiring the transportation duration of the central air conditioning unit in the transportation process; and the product of the transportation time and the vibration coefficient represents the service life loss of the central air conditioning unit, and the product is uploaded to the cloud end to correct the twin model.
In some embodiments of the present application, the installation parameters include a second refrigerant charge amount and a pipeline length;
the cloud end sets a locking function for the central air conditioning unit corresponding to the manufacturing code; and when the installation parameters are uploaded to the cloud to obtain the manufacturing codes, the cloud unlocks the user operation modes of the central air conditioning unit corresponding to the manufacturing codes.
In some embodiments of the present application, the method further comprises:
configuring a unit failure experience set function comprising an operation parameter variable in the twin model;
and when judging that the key component fault early warning exists through the operation parameters and the key component failure model, calling a unit fault failure experience set function, and confirming the key component fault early warning when the operation parameters are brought into the operation parameter variables.
In some embodiments of the present application, a central air conditioning unit fault monitoring system is provided, which includes:
a cloud end;
the central air conditioning unit is configured with a unique manufacturing code, and a twin model generated by copying an original model under the manufacturing code is stored in the cloud end; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which are relevant to the unit design parameters;
the manufacturing parameter uploading unit is arranged on a production manufacturing line of the central air conditioning unit, is in communication connection with the cloud end, and uploads the acquired manufacturing parameters to the cloud end by acquiring the manufacturing codes and acquiring the manufacturing parameters;
the transportation parameter uploading unit is arranged on the central air conditioning unit, is in communication connection with the cloud end, and acquires the transportation parameters to upload the transportation parameters to the cloud end;
the installation parameter uploading unit is in communication connection with the cloud end, inputs the installation parameters by an after-sales service department and uploads the installation parameters to the cloud end;
the operation parameter uploading unit is respectively in communication connection with the central air conditioning unit and the cloud end, and acquires the operation parameters to upload the operation parameters to the cloud end;
and the processing module is arranged at the cloud end, calls the manufacturing parameters, the transportation parameters and the installation parameters to correct the twin model, and judges whether key component failure early warning exists according to the received operation parameters and the twin model.
In some embodiments of the present application, a crew failure experience set function is configured in the twin model, and includes an operation parameter variable;
and when the fault early warning of the key component is judged to exist through the operation parameters and the key component failure model, the processing module calls a unit fault failure experience set function, and confirms the fault early warning of the key component when the operation parameters are brought into the operation parameter variables.
In some embodiments of the present application, the manufacturing parameter uploading unit is an MES system; the manufacturing code is a code of the MES system; uploading the manufacturing parameters to the cloud through the MES system;
the transportation parameter uploading unit is an internet of things module and can detect position signals of the central air conditioning unit at regular time and upload the position signals to the cloud end; the processing module of the cloud end accumulates the duration of continuous movement according to the received position signal to obtain the transportation duration; the processing module is configured with a vibration coefficient, calculates the product of the transportation time and the vibration coefficient, and corrects the twin model;
the installation parameter uploading unit is an after-sale service system and comprises an after-sale service system terminal used for inputting the installation parameters;
and the operation parameters are uploaded to the cloud terminal through the Internet of things module.
In some embodiments, the present application provides a central air conditioning unit, comprising:
the unique manufacturing code is configured on the central air conditioning unit and used for marking the twin model corresponding to the central air conditioning unit and uploading the manufacturing parameters, the transportation parameters, the installation parameters and the operation parameters to correct the twin model corresponding to the manufacturing code;
the transportation parameter uploading module is in communication connection with the cloud end and acquires the transportation parameters to upload the transportation parameters to the cloud end;
and the operation parameter uploading unit is in communication connection with the cloud end and acquires the operation parameters to upload the operation parameters to the cloud end.
Other features and advantages of the present invention will become more apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic composition diagram according to an embodiment;
FIG. 2 is a schematic diagram of generating a twin model from manufacturing coding according to an embodiment;
FIG. 3 is a schematic diagram of manufacturing parameter collection and uploading during a manufacturing process according to an embodiment;
FIG. 4 is a schematic diagram of collecting transport parameters and uploading during transport according to an embodiment;
FIG. 5 is a schematic diagram of installation parameters uploaded by an installation process according to an embodiment;
FIG. 6 is a schematic flow chart according to an embodiment;
FIG. 7 is a schematic flow chart diagram according to an embodiment;
fig. 8 is a schematic flow diagram according to an embodiment.
Reference numerals:
1. a cloud end; 2. a production and manufacturing process; 3. a transportation process; 4. mounting; 5. running process; 6. a central air conditioning unit; 7. a twin model; 8. a MES system; 9. and (4) an after-sale service system terminal.
Detailed Description
The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all of the embodiments. All other embodiments obtained by a person of ordinary skill in the art based on the embodiments in the present application without making any creative effort belong to the protection scope of the present application.
In the description of the present application, it is to be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience in describing the present application and simplifying the description, but do not indicate or imply that the referred device or element must have a particular orientation, be constructed in a particular orientation, and be operated, and thus should not be construed as limiting the present application.
The terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present application, the meaning of "a plurality" is two or more unless otherwise specified.
In the description of the present application, it should be noted that, unless otherwise explicitly stated or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, a fixed connection, a detachable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present application can be understood in a specific case by those of ordinary skill in the art.
In the present invention, unless otherwise expressly stated or limited, "above" or "below" a first feature means that the first and second features are in direct contact, or that the first and second features are not in direct contact but are in contact with each other via another feature therebetween. Also, the first feature being "on," "above" and "over" the second feature includes the first feature being directly on and obliquely above the second feature, or merely indicating that the first feature is at a higher level than the second feature. "beneath," "under" and "beneath" a first feature includes the first feature being directly beneath and obliquely beneath the second feature, or simply indicating that the first feature is at a lesser elevation than the second feature.
The following disclosure provides many different embodiments or examples for implementing different features of the invention. To simplify the disclosure of the present invention, the components and arrangements of specific examples are described below. Of course, they are merely examples and are not intended to limit the present invention. Furthermore, the present invention may repeat reference numerals and/or letters in the various examples, such repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. In addition, the present invention provides examples of various specific processes and materials, but one of ordinary skill in the art may recognize applications of other processes and/or uses of other materials.
The central air-conditioning system is mainly divided into three types: the system comprises an all-air system, an all-water system and an all-refrigerant system.
The whole air system takes air as a conveying medium, the outdoor unit host machine generates cold/heat in a centralized manner, and the return air returned from each room is subjected to cold/heat treatment to carry the cold/heat into each room so as to perform air conditioning on each indoor room or space. The air transmission and distribution system for realizing indoor air return and air supply is realized by an air pipe; the full air system needs larger floor height due to larger building space occupied by the arranged air pipes, so that the popularization and the application of the full air central air-conditioning system have certain limitations.
The conveying medium of the full water system is usually water, cold/heat is generated in a centralized manner through the outdoor host machine, and then the heat exchange is carried out between the cold/heat and the conveying medium, so that the conveying medium carries the cold/heat to be conveyed to each indoor terminal device through a water pipeline; the cold/hot water exchanges heat with the indoor air at the end unit to produce cold/hot air for temperature conditioning of the respective indoor room or space. The end unit is primarily a fan coil. The central air conditioner of the full water system is popular with users because of small temperature difference of air supply, good temperature stability, small humidity change and convenient maintenance, and because the application of the frequency conversion technology is more and more extensive recently, the outdoor host of the central air conditioner of the full water system uses the frequency conversion compression, and the central air conditioner is divided into more than two parts because of low energy consumption.
The whole refrigerant system is characterized in that the cooling and heating treatment of each room is carried out by independent indoor units, and each indoor unit carries out heat exchange with an outdoor host computer module where the indoor unit is located through a closed refrigerant loop. Refrigerant (mainly R410A) is used as a conveying medium, and is conveyed to a plurality of indoor units by an outdoor unit through a refrigerant pipeline; the flow of the refrigerant in the whole system is controlled and adjusted, so that the indoor load is timely met. Because the cold/heat is conveyed in the refrigerant pipeline through the refrigerant, the requirement on energy conservation is high during installation, and the requirement on construction level is high. That is, strict heat insulation treatment needs to be performed on the refrigerant pipe. And because the temperature is quickly reduced and increased, the device has certain advantages.
The central air conditioning system, whether it is an all-air system, an all-water system, or an all-refrigerant system, includes a compressor, a condenser, an expansion valve, and an evaporator, and completes refrigerant circulation by using the compressor, the condenser, the expansion valve, and the evaporator. The refrigerant cycle includes a series of phase change processes, which involve compression, condensation, expansion and evaporation, so that the refrigerant absorbs or releases heat in the process, thereby realizing refrigeration or heating of the indoor space.
Specifically, a low-temperature and low-pressure refrigerant enters the compressor, and the compressor compresses the refrigerant gas into a high-temperature and high-pressure state and discharges the compressed refrigerant gas. The discharged refrigerant gas flows into the condenser. The condenser condenses the compressed refrigerant into a liquid phase, and heat is released into the heat exchange medium through the condensation process.
The expansion valve expands the liquid-phase refrigerant in a high-temperature and high-pressure state condensed in the condenser into a low-pressure liquid-phase refrigerant. The low-pressure liquid-phase refrigerant reaches and enters the evaporator to be evaporated, a low-temperature and low-pressure gaseous refrigerant is generated, and the refrigerant gas in a low-temperature and low-pressure state is returned to the compressor.
The evaporator can achieve a cooling effect by heat-exchanging with a material to be cooled using latent heat of evaporation of a refrigerant. The purpose of regulating the temperature of the indoor space can be achieved by either the heat release of the condenser or the heat absorption of the evaporator throughout the cycle.
The central air conditioning unit in this application is the host computer including compressor and outdoor heat exchanger, and it mainly compresses the refrigerant and the phase change of refrigerant produces cold volume/heat through the compressor. Of course, the outdoor unit may be an outdoor unit of an all-air system, a cold water unit of an all-water system, or a multi-connected outdoor unit of an all-refrigerant system.
Because the central air conditioning unit supplies cold or heat for a plurality of indoor rooms through one host, once the central air conditioning unit breaks down, the condition of large-area cold/heat stop is easily caused, and great loss is caused or inconvenience is brought to the life of people. In addition, once the central air conditioning unit fails, the maintenance period is long and the maintenance cost is high, so that a user generates large economic loss.
Referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7 and fig. 8, the method for monitoring the faults of the central air conditioning unit includes establishing an original model, which includes unit design parameters and a key component failure model; and the key component failure model and the unit design parameters have correlation. Unit design parameters
The central air conditioning unit fault monitoring method further comprises causing the central air conditioning unit 6 to generate a twin model 7 that is a replica of the original model; the twin model 7 of the central air-conditioning unit 6 is corrected by the manufacturing parameters in the production manufacturing process 2 to the component design parameters, the transportation parameters in the transportation process 3 to the unit design parameters, and the installation parameters in the installation process 4 to the unit design parameters. The central air conditioning unit 6 is an entity unit of the central air conditioning unit.
The method for monitoring the faults of the central air-conditioning unit also comprises the steps of acquiring the operation parameters of the central air-conditioning unit 6 in the operation process 5, synchronizing the acquired operation parameters into a twin model 7 of the central air-conditioning unit 6, and judging whether related key components form failure early warning or not according to a key component failure model which is relevant to the unit design parameters of the twin model 7; and if the key component failure early warning exists, performing fault early warning.
The central air conditioning unit fault monitoring method of the invention corrects the twin model 7 corresponding to the central air conditioning unit 6 by obtaining the manufacturing parameters with difference in the production and manufacturing process 2, the transportation parameters with difference in the transportation process 3 and the installation parameters with difference in the installation process 4 of the central air conditioning unit 6, so that the twin model 7 of the central air conditioning unit 6 and the entity machine of the central air conditioning unit 6 have completely the same unit parameters and operation parameters, and the statistics of the operation wear generated by the operation state under the operation parameters in the operation process 5 of the central air conditioning unit 6 is more accurate; therefore, the failure early warning of the key components is more accurate, reliable basis is provided for after-sale failure early warning, the accuracy of the failure early warning is improved, the maintenance period is shortened, the maintenance efficiency is improved, and the maintenance cost is reduced. The unit parameters include structure and system parameters, which are the actual configuration of the unit design parameters.
Namely, when the fault early warning is generated, the central air conditioning unit 6 is prompted to indicate the fault to be generated or the component to be damaged, so that the possibility of providing advanced service and pre-fault service for the central air conditioning unit after sale is provided, the maintenance is completed before the central air conditioning unit 6 is damaged, the loss and the maintenance cost of a user are reduced, the difficulty of searching for the fault of the central air conditioning unit after sale team is reduced, the time of fault analysis of the after sale maintenance team is shortened, and the maintenance efficiency is improved.
In addition, the method for monitoring the faults of the central air conditioning unit provides collection and monitoring of parameters of the whole life cycle of the central air conditioning unit 6 in the production manufacturing stage, the transportation stage, the installation stage and the operation stage, so that the physical machine of the central air conditioning unit 6 and the twin model 7 have more sufficient consistency, and the problem of large deviation of the fault prediction of the physical machine of the central air conditioning unit 6 and the fault prediction of the twin model 7 is effectively solved.
The invention utilizes the digital twin technology to supervise the whole life cycle of the central air-conditioning unit, and the whole machine operation state is monitored by updating, correcting and synchronizing the twin model 7 from the complete machine production completion modeling to the bumping and vibration data of the central air-conditioning unit 6 in the transportation process to the installation and operation data of the central air-conditioning unit 6. And the configured key component failure model is added, so that the reason for the failure occurrence and the possible failure phenomenon can be predicted in advance. A brand-new fault prediction mode is provided, possible fault reasons are quickly positioned, and the influence of unit faults is minimized.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, the original model is saved in the cloud 1. The central air conditioning unit 6 is configured with a unique manufacturing code during production and manufacturing, and when the manufacturing code is used for the first time, the manufacturing code is uploaded to the cloud end 1 and stored in the cloud end 1, and a twin model 7 with an original model copied is correspondingly stored.
And uploading the manufacturing parameters in the production manufacturing process 2, the transportation parameters in the transportation process 3, the installation parameters in the installation process 4 and the operation parameters in the operation process 5 of the central air-conditioning unit 6 to the cloud end 1 to correct and synchronize the corresponding twin model 7.
According to the fault monitoring method for the central air conditioning unit, the manufacturing code which corresponds to the central air conditioning unit 6 only is arranged to follow the central air conditioning unit 6, and the manufacturing code is stored in the cloud end 1, so that parameters of the central air conditioning unit 6 in the production, manufacturing, transportation, installation and operation processes 5 are uploaded to the twin model 7 corresponding to the central air conditioning unit 6, and real-time updating and correction of the twin model 7 are possible.
The twin model 7 synchronizes real-time data of the physical machine of the central air-conditioning unit 6 and predicts failure in real time at the cloud 1, so that failure reasons of real machines are predicted in advance, an effective solution is provided in a targeted manner, and prediction efficiency and notification efficiency are improved.
According to some embodiments of the present application, referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, and fig. 8, the unit design parameters of the original model include structural design parameters, circulation system design parameters, electrical design parameters, and the like, which are obtained through optimization and improvement of multiple vibration tests, noise tests, enthalpy difference tests, electrical safety tests, and EMC tests, and meet requirements of system capacity, structural strength, electrical safety, and EMC.
The key component failure model is life parameters and the like of key components selected by the unit under specific operation parameters, such as the life parameters and the like of a compressor under specific pressure, voltage and current; switching times of the electromagnetic valve under specific voltage and current; the service life of the refrigerant pipeline under the specific pipeline pressure; the life of the screw under specific torque and vibration, etc.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, and 8, the original model includes a plurality of models corresponding to different models or capacities of the central air conditioning unit. The production code selects the copied original model to generate the twin model 7 according to the model or the capability of the central air conditioning unit 6 when uploading to the cloud 1.
According to the fault monitoring method of the central air conditioning unit, multiple original models are uploaded to the cloud end 1 according to the machine types or the capabilities, so that the central air conditioning unit units 6 of different machine types or different capabilities use different original models, the pertinence and the accuracy of the original models are improved, and the accuracy of the twin models 7 is further improved.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, manufacturing code is configured onto the central air conditioning unit 6 during the central air conditioning unit 6 production manufacturing process 2 and always follows the full life cycle of the central air conditioning unit 6.
The correction of the twin model 7 in the production and manufacturing process 2 comprises the correction of a structure position and a connection parameter, the correction of a first refrigerant charge quantity parameter, the correction of a line inspection operation high/low pressure parameter, the correction of an air tightness parameter, the correction of an electrical safety parameter and the like.
According to the fault monitoring method for the central air conditioning unit, the modification of the structural position and the connection parameter, the modification of the first refrigerant charging quantity parameter, the modification of the line inspection operation high/low pressure parameter, the modification of the air tightness parameter and the modification of the electrical safety parameter in the production and manufacturing process 2 further cause the modification of the key component failure model, so that the life prediction of the key component is more accurate, and the fault prediction is more accurate.
According to some embodiments of the present application, referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, and fig. 8, the manufacturing code is encoded by the MES system 8 and uploaded to the cloud 1 through the MES system 8. Namely, the MES system 8 collects the manufacturing codes at the corresponding stations of the manufacturing parameters and uploads the manufacturing parameters.
The method for monitoring the faults of the central air conditioning unit utilizes an intelligent production management system used by the existing production line to complete the setting, acquisition and uploading of manufacturing parameters to the twin model 7 of the corresponding unit, thereby reducing the cost.
Of course, the manufacturing code may be encoded in other ways unrelated to MES system 8 and uploaded to cloud 1 in other wired or wireless ways. Such as a bus, the internet of things, the internet, etc.
For example, each screw holding torque is uploaded by the torque gun through MES system 8 to twin model 7; installation deviations of sheet metal parts and the like can be collected through a special laser scanning equipment model, and are uploaded to the cloud 1 through the MES system 8 to correct the twin model 7; before the box body of the central air conditioning unit 6 is sealed, the relative installation positions of key components such as the positions of copper pipes and the like are uploaded to the cloud end 1 through system scanning to be used for correcting the twin model 7.
In the aspect of system circulation, the first refrigerant filling amount, the line body detection system operation high/low pressure and air tightness detection data are uploaded to the cloud end 1 through the MES system 8 to correct the twin model 7, and some detection results can be used as standard working condition parameters of the twin model 7 in the later operation and can achieve a correction effect on the service life evaluation of key components in the central air conditioning unit 6.
Electrical safety data, all electrical safety parameters are completely recorded and uploaded after an entity machine of the central air-conditioning unit 6 is detected by a production line body; the electrical parameters of the central air conditioning unit 6 under the standard working condition, such as the peak current of the primary side and the secondary side, the instantaneous voltage and the like, are uploaded to the cloud 1 to correct the twin model 7.
According to some embodiments of the present application, referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, and fig. 8, the vibration coefficient is set, which is obtained according to an average value of the set values of the comprehensive simulation of multiple road conditions, and which is greater than the average value.
Collecting the transportation duration in the transportation process 3; the transport parameter is equal to the product of the transport time and the vibration coefficient, which characterizes the life loss of the transport parameter to the central air conditioning unit 6.
The time for collecting transportation can be acquired through an internet of things module configured in the unit. Specifically, in the transportation process 3 of the unit, the internet of things module acquires the geographic position and reports the geographic position to the cloud end 1, when the reported geographic position changes continuously, the cloud end 1 accumulates and times the time that the geographic position changes continuously until the geographic position does not change and the geographic position detection function is closed, and the time that all the geographic positions change continuously is superposed to obtain the transportation duration.
And uploading the transportation duration to the cloud 1, and calculating the product of the transportation duration and the vibration coefficient to obtain the transportation parameters. And correcting the failure model of the key component in the twin model 7, so that the judgment of whether the key component reaches failure early warning or not is more accurate according to the operation parameters when the central air conditioning unit 6 operates.
According to the fault monitoring method of the central air conditioning unit, the continuous reporting of the geographic position is achieved by configuring the Internet of things module, and the cloud 1 judges whether the central air conditioning unit is in a transportation state or not according to the reported geographic position and accumulates and calculates the transportation time; the cloud 1 determines the service life loss of the central air conditioning unit 6 caused by the vibration loss caused by transportation according to the transportation duration, and reflects the service life loss on the key component failure model through the correction of the twin model 7.
The product of the transport time length and the vibration coefficient represents the loss of the service life of the entity machine caused by vibration. In order to guarantee that the fault can be reported before the fault occurs, the vibration coefficient is corrected to be a value higher than the average value according to comprehensive simulation of various road conditions.
According to some embodiments of the present disclosure, referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, and fig. 8, the installation parameters include a second refrigerant charge amount and a pipe length.
The twin model 7 is provided with the correlation between the total refrigerant filling amount of the system, the length of a pipeline and a key component failure model; the sum of the second charge in the installation process 4 and the first refrigerant charge in the production process 2 and the length of the refrigerant pipeline affect the service life of the key components. During installation, the second refrigerant supplement charge amount and the pipeline length are uploaded to the cloud end 1 twin model 7 to correct the failure model of the key component, so that failure early warning of a system where the central air conditioning unit 6 is located is more accurate in the running state, and further fault early warning of the central air conditioning unit is more accurate.
According to some embodiments of the present application, referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, and fig. 8, the cloud 1 sets a locking function for the central air conditioning unit 6 corresponding to the manufacturing code; that is, when the central air conditioning unit 6 under the manufacturing code of the cloud 1 has no second refrigerant charge amount and no pipeline length to upload, the central air conditioning unit 6 is only allowed to operate in a debugging state, but cannot operate in a user use state; and when the twin model 7 under the corresponding manufacturing code receives the data of the second refrigerant charge amount and the pipeline length, the user operation mode is unlocked.
According to the central air-conditioning fault early warning method, the cloud data is completed by setting the user mode locking function to limit the after-sales department to standardize, so that the twin model 7 system of the central air-conditioning unit 6 has complete data, and the fault early warning accuracy is improved.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, after installation of the central air conditioning unit 6, the transportation parameters are not updated and its modification of the twin model 7 is stopped. The acquisition of the geographical position is confirmed by reporting position information through an internet of things module of the central air-conditioning unit 6. For example, when the reported cell ID changes, it indicates that the unit is in transit. After the central air conditioning unit 6 is installed, the internet of things module is enabled to convert the working mode through after-sale confirmation installation, and acquisition and uploading of the geographical position are finished.
According to the fault monitoring method for the central air conditioning unit, after installation is confirmed, the geographic position acquisition function is in a dormant or stop state, and power consumption of the Internet of things module is reduced; when the internet of things module is used for uploading other parameters (such as operation parameters), the communication efficiency of the internet of things module is improved.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, and 8, installation parameters in the installation process 4 are uploaded to the cloud 1 through an after-sales service system. The after-sales service system comprises an after-sales service system terminal 9 for inputting installation parameters and uploading the installation parameters to the cloud end 1 through the after-sales service system.
Specifically, the installation parameters are uploaded to an after-sales service system through the after-sales service system; and then, synchronizing all installation parameters of the after-sales service system into the twin model through cloud docking. Namely, the twin model 7 corresponding to the manufacturing code is invited through the cloud 1 and receives the installation parameters sent by the after-sales service cloud 1.
In addition, when the twin model 7 of the cloud 1 has a fault early warning, the central air conditioning unit 6 sends a fault early warning message to an after-sales service system through the communication between the cloud 1 and the cloud 1, or directly sends a fault early warning message to a user controller or a bound intelligent mobile terminal to remind of maintenance or repair in advance, so that the real fault is avoided.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, and 8, the operation parameters include a compressor pressure parameter, a compressor electrical parameter, a solenoid valve flow parameter, a solenoid valve switching frequency, an expansion valve electrical parameter, an expansion valve flow parameter, a four-way valve electrical parameter, a four-way valve switching frequency, a vibration parameter, a refrigerant high-low pressure parameter, an evaporation temperature, a condensation temperature, a superheat degree, a supercooling degree, and the like.
The acquisition of the operating parameters is respectively realized by the acquisition of sensors arranged in the unit units and the control information of the controller of the central air-conditioning unit 6.
In the method for monitoring the faults of the central air conditioning unit, the operation of the central air conditioning unit 6 is monitored under each operation parameter, once abnormal parameters are found, the twin model 7 is used for analyzing to obtain whether faults occur or not and the tolerance time, and fault early warning and maintenance reminding are carried out on an after-sales service system, a user controller or a bound intelligent mobile terminal, so that the loss of sudden faults is avoided.
According to some embodiments of the present application, referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, and fig. 8, the uploading of the operation parameters may be implemented through a communication connection between the internet of things module and the cloud 1, or through a communication connection between a network communication module arranged in the central air conditioning unit 6 and the internet.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, the unit anomaly is mainly caused by an anomaly of a critical component. The key components include a compressor, a solenoid valve, a four-way valve, etc. The main failure models of the respective critical components are input into the twin model 7. When the key parts reach the natural service life or the extreme working condition impacts the key parts to cause damage, the corresponding parts are reminded to replace after sale and users in advance.
For example, the switch life data of the electromagnetic valve is determined during model selection in a new product development stage. The actual operation data of the real machine is synchronized into the twin model 7 in real time, when the electromagnetic valve is close to the service life threshold value, the possibility of occurrence of faults is realized, then the related operation parameters are focused, and the accuracy of fault prediction is further improved.
Therefore, failure models of key parts influencing the operation of the unit are recorded in the twin model 7 of the central air-conditioning unit 6, and the failure models of the key parts are obtained by fitting the life test and the temperature impact test results of the key parts.
In addition, when the key component which generates failure early warning or fails is replaced, the parameters of the replaced key component and the failure model are synchronized into the twin model 7, and the switching times and the service life of the key component are recalculated.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, a unit failure experience set function is configured in the twin model 7, including operating parameter variables. When the key component fault is judged through the operation parameters and the key component failure model, a fault failure experience set function is called, the operation parameters in the existing operation state are brought into the operation parameter variables, the failure of the key component is confirmed, and the accuracy of the fault occurrence is further confirmed.
The unit failure experience set function in the method for monitoring the faults of the central air conditioning unit in the embodiment is a data set formed after summarizing known existing fault forming reasons, and mainly comprises operation parameters of the unit before the fault happens. When the failure model of the key component is about to be attenuated to a critical value, the current operation data of the central air conditioning unit 6 is integrated and analyzed, and is compared with the operation parameters in the failure data set, and when the coincidence degree is higher, the reason of the problem can be timely positioned and the after-sales notice is given.
The application also discloses central air conditioning unit fault monitoring system, refer to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, fig. 8, including high in the clouds 1, central air conditioning unit 6, make parameter upload unit, transportation parameter upload unit, operation parameter upload unit, processing module.
The central air conditioning unit 6 is configured with a unique manufacturing code, and an original model is copied under the manufacturing code to generate a twin model 7 which is stored in the cloud 1; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which are relevant to the unit design parameters.
The manufacturing parameter uploading unit is arranged on a production manufacturing line of the central air conditioning unit 6, is in communication connection with the cloud end 1, and is used for acquiring a code of a manufacturing code, acquiring manufacturing parameters and uploading the acquired manufacturing parameters to the cloud end 1.
The transportation parameter uploading unit is arranged on the central air conditioning unit 6, is in communication connection with the cloud end 1, and acquires transportation parameters to upload to the cloud end 1.
The installation parameter uploading unit is in communication connection with the cloud end 1, installation parameters are input by an after-sale service department, and the installation parameters are uploaded to the cloud end 1.
The operation parameter uploading unit is respectively in communication connection with the central air conditioning unit 6 and the cloud end 1, acquires operation parameters and uploads the operation parameters to the cloud end 1.
The processing module is arranged on the cloud 1, calls the manufacturing parameters, the transportation parameters and the installation parameters to correct the twin model 7, and judges whether the key component failure early warning exists according to the received operation parameters and the twin model 7.
The central air conditioning unit fault monitoring system corrects the twin model 7 correspondingly arranged on the central air conditioning unit 6 by acquiring the manufacturing parameters with difference of the central air conditioning unit 6 in the production and manufacturing process 2, the transportation parameters with difference in the transportation process 3 and the installation parameters with difference in the installation process 4, so that the twin model 7 of the central air conditioning unit 6 and the entity machine of the central air conditioning unit 6 have completely same unit parameters and running parameters, and the running wear generated in the running state under the running parameters in the running process 5 is more accurately counted; and the failure early warning of the key component judged by the key component failure model related to the unit parameters is more accurate, reliable basis is provided for after-sale failure early warning, the accuracy of the failure early warning is improved, the maintenance period is shortened, the maintenance efficiency is improved, and the maintenance cost is reduced.
According to some embodiments of the present application, with reference to fig. 1, 2, 3, 4, 5, 6, 7, 8, a set of crew failure experiences is configured in the twin model 7, including operating parameter variables.
When the critical component fault early warning is judged to exist through the operation parameters and the critical component failure model, the processing module calls a set of unit fault failure experience sets, and the critical component fault early warning is confirmed when the operation parameters are brought into the operation parameter variables.
According to some embodiments of the present application, referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, fig. 8, the manufacturing parameter uploading unit is an MES system 8; the manufacturing code is the code of the MES system 8; the manufacturing parameters are uploaded to the cloud 1 via the MES system 8.
The transportation parameter uploading unit is an internet of things module and can detect position signals of the central air conditioning unit 6 at regular time and upload the position signals to the cloud 1; the processing module of the cloud 1 accumulates the duration of the continuous movement according to the received position signal to obtain the transportation duration; the processing module is configured with a vibration coefficient, calculates the product of the transport time and the vibration coefficient, and corrects the twin model 7.
The installation parameter uploading unit is an after-sales service system, and includes an after-sales service system terminal 9 for inputting installation parameters. The operation parameters are uploaded to the cloud 1 through the internet of things module.
In some embodiments of the present application, referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, and fig. 8, there is provided a central air conditioning unit 6, which includes a unique manufacturing code, a transportation parameter uploading module, and an operation parameter uploading unit.
The unique manufacturing code is configured on the central air conditioning unit 6 for marking the twin model 7 corresponding to the central air conditioning unit 6 and for uploading manufacturing parameters, transportation parameters, installation parameters and operation parameters.
The transportation parameter uploading module is in communication connection with the cloud end 1, acquires transportation parameters and uploads the transportation parameters to the cloud end 1.
The operation parameter uploading unit is in communication connection with the cloud end 1, and obtains operation parameters to be uploaded to the cloud end 1.
According to some embodiments of the application, the transportation parameter uploading module and the operation parameter uploading unit share the internet of things module.
In the foregoing description of embodiments, the particular features, structures, materials, or characteristics may be combined in any suitable manner in any one or more embodiments or examples.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (10)
1. A fault monitoring method for a central air conditioning unit is characterized by comprising the following steps:
establishing an original model; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which are relevant to the unit design parameters;
the central air-conditioning unit copies the original model to generate a twin model, and obtains manufacturing parameters in the production and manufacturing process to correct the twin model;
acquiring transportation parameters in the transportation process to correct the twin model;
obtaining installation parameters in the installation process to correct the twin model;
and acquiring operation parameters in the operation process, synchronizing the operation parameters to the twin model, and judging whether a key component failure early warning exists according to the key component failure model in the twin model.
2. The central air conditioning unit fault monitoring method according to claim 1, wherein the raw model is stored in a cloud;
storing a unique manufacturing code corresponding to the central air conditioning unit in the cloud; storing the unique twin model under the manufacturing code;
the original models of the central air conditioning units with different models or capacities correspond to different unit design parameters and different key component failure models; and importing the corresponding original model into the manufacturing code according to the model or the capability of the central air conditioning unit to generate the twin model.
3. The central air conditioning unit fault monitoring method according to claim 2, wherein the manufacturing code is a code of an MES system, which is configured to the central air conditioning unit during the manufacturing process and always follows the full life cycle of the central air conditioning unit;
in the production and manufacturing process, code collection is carried out on each station through the MES system, the manufacturing parameters are obtained, and the obtained manufacturing parameters are uploaded to the cloud;
the manufacturing parameters comprise structural connection parameters, structural layout parameters, first refrigerant charging quantity, system operation high/low pressure, air tightness and electrical safety parameters.
4. The method for monitoring the faults of the central air conditioning unit as claimed in claim 1, wherein a vibration coefficient is set, and the vibration coefficient is obtained according to an average value of comprehensive simulation of various road conditions; the vibration coefficient is greater than the average value;
acquiring the transportation time of the central air conditioning unit in the transportation process; and the product of the transportation time and the vibration coefficient represents the service life loss of the central air conditioning unit, and the product is uploaded to the cloud end to correct the twin model.
5. The central air conditioning unit fault monitoring method according to claim 4, wherein the installation parameters include a second refrigerant charge amount, a pipeline length;
the cloud end sets a locking function for the central air conditioning unit corresponding to the manufacturing code; and when the installation parameters are uploaded to the cloud to obtain the manufacturing codes, the cloud unlocks the user operation modes of the central air conditioning unit corresponding to the manufacturing codes.
6. The central air conditioning unit fault monitoring method according to any one of claims 1 to 5, characterized by further comprising:
configuring a unit failure experience set function comprising an operation parameter variable in the twin model;
and when judging that the key component fault early warning exists through the operation parameters and the key component failure model, calling a unit fault failure experience set function, and confirming the key component fault early warning when the operation parameters are brought into the operation parameter variables.
7. A central air conditioning unit fault monitoring system, characterized by includes:
a cloud end;
the central air conditioning unit is configured with a unique manufacturing code, and a twin model generated by copying an original model under the manufacturing code is stored in the cloud end; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which are relevant to the unit design parameters;
the manufacturing parameter uploading unit is arranged on a production manufacturing line body of the central air conditioning unit, is in communication connection with the cloud end, and uploads the acquired manufacturing parameters to the cloud end through code acquisition of the manufacturing codes and acquisition of the manufacturing parameters;
the transportation parameter uploading unit is arranged on the central air conditioning unit, is in communication connection with the cloud end, and acquires the transportation parameters to upload the transportation parameters to the cloud end;
the installation parameter uploading unit is in communication connection with the cloud end, inputs the installation parameters by an after-sales service department and uploads the installation parameters to the cloud end;
the operation parameter uploading unit is respectively in communication connection with the central air conditioning unit and the cloud end, and acquires the operation parameters to upload the operation parameters to the cloud end;
and the processing module is arranged at the cloud end, calls the manufacturing parameters, the transportation parameters and the installation parameters to correct the twin model, and judges whether key component failure early warning exists according to the received operation parameters and the twin model.
8. The central air conditioning unit fault monitoring system of claim 7,
configuring a unit failure experience set function comprising an operation parameter variable in the twin model;
and when the critical component failure early warning is judged to exist through the operating parameters and the critical component failure model, the processing module calls the unit failure experience set function, and confirms the critical component failure early warning when the operating parameters are brought into the operating parameter variables.
9. Central air conditioning unit fault monitoring system according to claim 7 or 8,
the manufacturing parameter uploading unit is an MES system; the manufacturing code is a code of the MES system; uploading the manufacturing parameters to the cloud through the MES system;
the transportation parameter uploading unit is an internet of things module and can detect position signals of the central air conditioning unit at regular time and upload the position signals to the cloud end; the processing module of the cloud end accumulates the duration of continuous movement according to the received position signal to obtain the transportation duration; the processing module is configured with a vibration coefficient, calculates the product of the transportation time and the vibration coefficient, and corrects the twin model;
the installation parameter uploading unit is an after-sale service system and comprises an after-sale service system terminal used for inputting the installation parameters;
and the operation parameters are uploaded to the cloud terminal through the Internet of things module.
10. A central air conditioning unit, comprising:
the unique manufacturing code is configured on the central air conditioning unit and used for marking the twin model corresponding to the central air conditioning unit and uploading the manufacturing parameters, the transportation parameters, the installation parameters and the operation parameters to correct the twin model corresponding to the manufacturing code;
the transportation parameter uploading module is in communication connection with the cloud end and acquires the transportation parameters to upload the transportation parameters to the cloud end;
and the operation parameter uploading unit is in communication connection with the cloud end and acquires the operation parameters to upload the operation parameters to the cloud end.
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