CN114923261B - Central air conditioner unit fault monitoring method and system and central air conditioner unit - Google Patents
Central air conditioner unit fault monitoring method and system and central air conditioner unit Download PDFInfo
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- CN114923261B CN114923261B CN202210480366.8A CN202210480366A CN114923261B CN 114923261 B CN114923261 B CN 114923261B CN 202210480366 A CN202210480366 A CN 202210480366A CN 114923261 B CN114923261 B CN 114923261B
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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
- F24F11/63—Electronic processing
- F24F11/64—Electronic processing using pre-stored data
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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
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a fault monitoring method and system of a central air conditioner unit and the central air conditioner unit; the fault monitoring method of the central air conditioning unit comprises the following steps of; establishing an original model; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which have correlation with each unit design parameter; the central air conditioning unit replicates the original model to generate a twin model, and acquires manufacturing parameters in the production and manufacturing process to correct the twin model; the transportation parameters are acquired 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 to synchronize to the twin model in the operation process, and judging whether critical component failure early warning exists according to the critical component failure model in the twin model. According to the invention, by correcting the twin model, 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 fault monitoring method and system of a central air conditioning unit and the central air conditioning unit.
Background
With the development of mapping technology from entity to virtual, digital twin technology has been developed that digitally reveals the physical world state. At present, the method has high-speed development in the fields of logistics, ships, aerospace, automobiles and the like, and helps a plurality of enterprises to complete the whole life cycle management from product research and development, manufacturing to later operation and maintenance.
The digital twin is to create a virtual model of the 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 for the physical entity by means of virtual-real interaction feedback, data fusion analysis, decision iteration optimization and the like.
The central air conditioning unit is a large-scale high-power unit, and the existing monitoring system is an error code arranged in the controller. That is, when the unit fails, the controller indicates the cause of the failure by displaying a corresponding error code. When the central air conditioning unit fails, the controller can only roughly determine the failure reason from the parameter change in the operation process of the air conditioner, so that the maintenance period is long, the maintenance efficiency is poor, the use of a user is influenced, large loss is easily caused to the user, and the user experience is poor.
And once the central air conditioning unit fails, the central air conditioning unit is damaged, and damaged parts or parts damaged by the failure of the damaged parts are required 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 not form the prior art that is already known to those of ordinary skill in the art.
Disclosure of Invention
Aiming at the problems pointed out in the background art, the invention discloses a fault monitoring method and system for a central air conditioner unit and the central air conditioner unit, which are characterized in that a digital twin model corresponding to the central air conditioner unit is arranged, the digital twin model is corrected through actual production, manufacturing, transportation and installation conditions, and whether critical component failure early warning exists or not is judged through real-time synchronous operation parameters, so that full life cycle fault monitoring and early fault early warning of the central air conditioner unit are realized, the maintenance efficiency of the central air conditioner unit is improved, and the maintenance cost of the central air conditioner unit is reduced.
In order to achieve the aim of the invention, the invention is realized by adopting the following technical scheme:
in some embodiments of the present application, a fault monitoring method for a central air conditioning unit is provided, including:
Establishing an original model; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which have correlation with each unit design parameter;
the central air conditioning unit replicates the original model to generate a twin model, and acquires manufacturing parameters in the production and manufacturing process to correct the twin model;
the transportation parameters are acquired 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 to synchronize to the twin model in the operation process, and judging whether critical component failure early warning exists according to the critical component failure model in the twin model.
Compared with the prior art, the invention has the advantages and positive effects that:
according to the fault monitoring method of the central air conditioner unit, the twin model correspondingly arranged on the central air conditioner unit is corrected by acquiring the manufacturing parameters with differences in the production and manufacturing processes, the transportation parameters with differences in the transportation process and the installation parameters with differences in the installation process of the central air conditioner unit, so that the twin model of the central air conditioner unit and the entity machine of the central air conditioner unit have identical unit parameters and operation parameters, and the statistics of operation wear generated by the operation state under the operation parameters in the operation process is more accurate; and then the failure early warning of the key component judged by the key component failure model related to the unit parameter is more accurate, a reliable basis is provided for after-sales failure early warning, the accuracy of the failure early warning is improved, the maintenance period is shortened, the maintenance efficiency is further improved, and the maintenance cost is reduced.
In some embodiments of the present application, the original model is stored in a cloud;
storing unique manufacturing codes corresponding to the central air conditioner unit units in the cloud; storing a unique twin model under the manufacturing code;
the original models of the central air conditioner units with different models or capacities correspond to different unit design parameters and different critical component failure models; and under the manufacturing code, importing the corresponding original model according to the model or the capacity of the central air conditioning unit to generate the twin model.
In some embodiments of the present application, the manufacturing code employs a code of an MES system that is configured onto the central air conditioning unit during the manufacturing process and that follows the full life cycle of the central air conditioning unit at all times; in the production and manufacturing process, code picking and manufacturing parameter acquisition are carried out at each station through the MES system, and the acquired manufacturing parameters are uploaded to the cloud;
the manufacturing parameters comprise a structure connection parameter, a structure layout parameter, a first refrigerant filling amount, a system operation high/low pressure, air tightness and an electrical safety parameter.
In some embodiments of the present application, a vibration coefficient is set, and the vibration coefficient is obtained according to an average value of comprehensive simulation of multiple road conditions; the vibration coefficient is greater than the average value;
acquiring the transportation time length of the central air conditioning unit in the transportation process; and the product of the transportation time length and the vibration coefficient represents the service life loss of the central air conditioning unit, and the service life loss is uploaded to the cloud 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; when the installation parameters are uploaded to the cloud to obtain the manufacturing codes, the cloud unlocks the user operation mode of the central air conditioning unit corresponding to the manufacturing codes.
In some embodiments of the present application, further comprising:
configuring a set of unit fault failure experience set functions in the twin model, which include operating parameter variables;
when judging that the critical component fault early warning exists through the operation parameters and the critical component fault model, calling the unit fault failure experience set function, and confirming the critical component fault early warning when the operation parameters are brought into the operation parameter variables.
In some embodiments of the present application, a fault monitoring system for a central air conditioning unit is provided, including:
and (3) cloud end.
The central air conditioner unit is configured with a unique manufacturing code, and copies an original model under the manufacturing code to generate a twin model and stores the twin model in the cloud; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which have correlation with the unit design parameters;
the manufacturing parameter uploading unit is arranged on a production and manufacturing line body of the central air conditioner unit and is in communication connection with the cloud end, and the acquired manufacturing parameters are uploaded to the cloud end by acquiring the manufacturing codes and the manufacturing parameters;
the transport parameter uploading unit is arranged on the central air conditioning unit and is in communication connection with the cloud end, and the transport parameter is obtained and uploaded to the cloud end;
the installation parameter uploading unit is in communication connection with the cloud end, and an after-sales service department inputs the installation parameters 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 to the cloud end;
And the processing module is arranged at the cloud end, invokes the manufacturing parameters, the transportation parameters and the installation parameters to correct the twin model, and judges whether critical component failure early warning exists according to the received operation parameters and the twin model.
In some embodiments of the present application, a set of empirical functions of unit failure is configured in the twinning model, which includes operating parameter variables;
when judging that the critical component fault early warning exists through the operation parameters and the critical component failure model, the processing module calls the unit fault failure experience set function, and confirms the critical component fault early warning 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; the manufacturing parameters are uploaded 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; 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 length and the vibration coefficient, and corrects the twin model;
The installation parameter uploading unit is an after-sales service system and comprises an after-sales service system terminal for inputting the installation parameters;
and the operation parameters are uploaded to the cloud through the Internet of things module.
In some embodiments of the present application, there is provided a central air conditioning unit, including:
the unique manufacturing code is configured on the central air conditioner unit and is used for marking a twin model corresponding to the central air conditioner unit and uploading manufacturing parameters, transportation parameters, installation parameters and operation parameters to correct the twin model corresponding to the manufacturing code;
the transport parameter uploading module is in communication connection with the cloud end, and acquires the transport parameters to upload 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 to the cloud end.
Other features and advantages of the present invention will become apparent upon review of the detailed description of the invention in conjunction with the drawings.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the drawings that are needed in the embodiments or the description of the prior art will be briefly described below, it will be obvious that the drawings in the following description are some embodiments of the present invention, and that other drawings can be obtained according to these drawings without inventive effort to a person skilled in the art.
FIG. 1 is a schematic diagram of the composition according to an embodiment;
FIG. 2 is a schematic diagram of generating a twinning model from a manufacturing code according to an embodiment;
FIG. 3 is a schematic diagram of the collection of manufacturing parameters and uploading of a manufacturing process according to an embodiment;
FIG. 4 is a schematic diagram of collecting transportation parameters and uploading during transportation according to an embodiment;
FIG. 5 is a schematic diagram of uploading installation parameters for an installation process according to an embodiment;
FIG. 6 is a flow diagram according to an embodiment;
FIG. 7 is a flow diagram according to an embodiment;
fig. 8 is a flow diagram according to an embodiment.
Reference numerals:
1. and (3) cloud end. 2. A production and manufacturing process; 3. a transportation process; 4. an installation process; 5. a running process; 6. a central air conditioning unit; 7. a twin model; 8. an MES system; 9. after-sales service system terminals.
Detailed Description
The following description of the embodiments of the present application will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all, of the embodiments of the present application. All other embodiments, which can be made by one of ordinary skill in the art without undue burden from the present disclosure, are within the scope of the present disclosure.
In the description of the present application, it should 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 the orientation or positional relationships shown in the drawings, merely to facilitate description of the present application and simplify the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present application.
The terms "first," "second," and the like, 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 defining "a first" or "a second" may explicitly or implicitly include one or more such feature. In the description of the present application, unless otherwise indicated, the meaning of "a plurality" is two or more.
In the description of the present application, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the terms in this application will be understood by those of ordinary skill in the art in a specific context.
In the present invention, unless expressly stated or limited otherwise, a first feature "above" or "below" a second feature may include both the first and second features being in direct contact, as well as the first and second features not being in direct contact but being in contact with each other through additional features therebetween. Moreover, a first feature being "above," "over" and "on" a second feature includes the first feature being directly above and obliquely above the second feature, or simply indicating that the first feature is higher in level than the second feature. The first feature being "under", "below" and "beneath" the second feature includes the first feature being directly under and obliquely below the second feature, or simply means that the first feature is less level than the second feature.
The following disclosure provides many different embodiments, or examples, for implementing different features of the invention. In order to simplify the present disclosure, components and arrangements of specific examples are described below. They are, of course, merely examples and are not intended to limit the invention. Furthermore, the present invention may repeat reference numerals and/or letters in the various examples, which are for the purpose of brevity and clarity, and which do not themselves indicate the relationship between the various embodiments and/or arrangements discussed. In addition, the present invention provides examples of various specific processes and materials, but one of ordinary skill in the art will recognize the application of other processes and/or the use of other materials.
The central air conditioning system is mainly divided into three types: an all-air system, an all-water system and an all-refrigerant system.
The air system uses air as a conveying medium, the main machine of the outdoor unit intensively generates cold/heat, and the main machine carries the cold/heat carried by the return air led back from each room and then sends the return air into each room, so as to air-condition each room or space. The air delivery and distribution system for realizing indoor return air and air supply is realized through an air pipe; the air system has a large building space occupied by the air pipes, and a large floor height is needed, so that the popularization and application of the air system have a certain limitation.
The whole water system conveying medium is usually water, cold/heat is intensively generated through an outdoor host, and then the whole water system conveying medium exchanges heat with the cold/heat conveying medium, so that the conveying medium carries the cold/heat and is conveyed to each indoor end device through a water pipeline; the cold/hot water exchanges heat with indoor air at the terminal device to generate cold/hot air for temperature adjustment of each indoor room or space. The end device is mainly a fan coil. The full-water system central air conditioner has the advantages of small air supply temperature difference, good temperature stability, small humidity change, convenient maintenance, capability of receiving user's favor by one machine, and more wide application of frequency conversion technology recently, so that the outdoor host of the full-water system central air conditioner uses frequency conversion compression, and the central air conditioner is divided into two parts due to low energy consumption.
The full refrigerant system is characterized in that the indoor units are used for performing cooling and heating treatment on each room, and each indoor unit performs heat exchange through a closed refrigerant loop and an outdoor host module where the indoor unit is located. The refrigerant (mainly R410A) is taken as a conveying medium, and the outdoor unit conveys the refrigerant to a plurality of indoor units through refrigerant pipelines; the indoor load is timely satisfied by controlling and adjusting the refrigerant flow in the whole system. The refrigerant is used for conveying cold/heat in the refrigerant pipeline, so that the energy-saving requirement is high during installation, and the construction level requirement is high. That is, the refrigerant line needs to be subjected to a severe heat insulating treatment. And the temperature is fast, so that the solar energy power generation device has certain advantages.
Central air conditioning systems, whether they be all-air systems, all-water systems, all-refrigerant systems, include a compressor, a condenser, an expansion valve, an evaporator, and complete refrigerant cycles by using the compressor, the condenser, the expansion valve, and the evaporator. The refrigerant circulation comprises a series of phase change processes, which relate to compression, condensation, expansion and evaporation, so that the refrigerant absorbs heat or releases heat in the process, and the indoor space is refrigerated or heated.
Specifically, a low-temperature low-pressure refrigerant enters a compressor, and the compressor compresses the refrigerant into a refrigerant gas in a high-temperature 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 formed by condensation in the condenser into a low-pressure liquid-phase refrigerant. The low-pressure liquid-phase refrigerant reaches and enters the evaporator to evaporate, generating low-temperature low-pressure gaseous refrigerant, and returning the refrigerant gas in a low-temperature low-pressure state to the compressor.
The evaporator may achieve a cooling effect by exchanging heat with a material to be cooled using latent heat of evaporation of a refrigerant. The purpose of adjusting the temperature of the indoor space can be achieved through the heat release of the condenser or the heat absorption of the evaporator in the whole cycle.
The central air conditioning unit in the application is a host machine comprising a compressor and an outdoor heat exchanger, and generates cold energy/heat mainly by compressing a refrigerant through the compressor and changing the phase state of the refrigerant. Of course, the outdoor unit of the all-air system, the cold water unit of the all-water system and the multi-connected outdoor unit of the all-refrigerant system can be adopted.
As the central air conditioning unit supplies cold or heat for a plurality of indoor rooms through one host, once the central air conditioning unit fails, the condition of large-area cold/warm stopping is easy to occur, and great loss is caused or inconvenience is brought to life of people. In addition, once the central air conditioning unit fails, the long maintenance period and the high maintenance cost can cause great economic loss for users.
Referring to fig. 1, fig. 2, fig. 3, fig. 4, fig. 5, fig. 6, fig. 7, fig. 8, a fault monitoring method for a central air conditioner unit of the present application includes establishing an original model, which includes a unit design parameter and a critical component failure model; and the critical component failure model has correlation with the unit design parameters. Design parameters of machine set
The central air conditioner unit fault monitoring method further comprises the steps of enabling the central air conditioner unit 6 to generate a twin model 7 which is a copy of the original model; the twin model 7 of the central air conditioner unit 6 corrects the component design parameters through the manufacturing parameters in the production and manufacturing process 2, corrects the unit design parameters through the transportation parameters in the transportation process 3, and corrects the unit design parameters through the installation parameters in the installation process 4. The central air conditioning unit 6 is a solid machine unit of the central air conditioning unit.
The central air conditioner unit fault monitoring method further comprises the steps of acquiring operation parameters of the central air conditioner unit 6 in the operation process 5, synchronizing the acquired operation parameters into a twin model 7 of the central air conditioner unit 6, and judging whether a critical component forms a fault early warning according to a critical component fault model which has correlation with unit design parameters of the twin model 7; and if the critical component failure early warning exists, carrying out fault early warning.
According to the fault monitoring method of the central air conditioner unit, the twin model 7 corresponding to the central air conditioner unit 6 is corrected by acquiring the manufacturing parameters with differences in the manufacturing process 2, the transportation parameters with differences in the transportation process 3 and the installation parameters with differences in the installation process 4 of the central air conditioner unit 6, so that the twin model 7 of the central air conditioner unit 6 and a solid machine of the central air conditioner unit 6 have the identical unit parameters and operation parameters, and the statistics of operation wear generated by the operation state of the operation parameters in the operation process 5 of the central air conditioner unit 6 is more accurate; and then the failure early warning of the key component is more accurate, a 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 comprise structure and system parameters, namely the actual configuration of the unit design parameters.
That is, when the fault early warning is generated, the central air conditioning unit 6 is prompted to prompt the fault or the component to be damaged, so that the possibility of providing advanced service and pre-fault service for the after-sale central air conditioning unit is provided, the maintenance of the central air conditioning unit 6 is completed before the damage, the loss and the maintenance cost of a user are reduced, the difficulty of searching the fault of the after-sale team of the central air conditioning unit is reduced, the time of analyzing the fault of the after-sale maintenance team is shortened, and the maintenance efficiency is improved.
In addition, the central air conditioning unit fault monitoring method provides collection and monitoring of parameters of the whole life cycle in the production and manufacturing stage, the transportation stage, the installation stage and the operation stage of the central air conditioning unit 6, so that the entity machine of the central air conditioning unit 6 has more sufficient consistency with the twin model 7, and the problem that the fault prediction deviation between the entity machine of the central air conditioning unit 6 and the fault prediction deviation of the twin model 7 is large is effectively solved.
The invention uses digital twin technology to monitor the whole life cycle of the central air conditioning unit, from complete modeling of the whole machine production to jolt and vibration data during transportation of the central air conditioning unit 6, to the data of installation and operation of the central air conditioning unit 6, and to monitor the running state of the whole machine synchronously through updating and correcting the twin model 7. The addition of the configured critical component failure model makes it possible to predict the cause of failure and possible failure phenomena in advance. A novel fault prediction mode is provided, possible fault reasons are rapidly located, 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 when manufactured, and the manufacturing code is uploaded to the cloud 1 when used for the first time and stored in the cloud 1, and correspondingly stores a twin model 7 including the original model.
And uploading the manufacturing parameters in the production and 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 1 to correct and synchronize the corresponding twin model 7.
The fault monitoring method of the central air conditioning unit of the embodiment realizes that parameters of the central air conditioning unit 6 in the production, transportation, installation and operation processes 5 are uploaded to the twin model 7 corresponding to the central air conditioning unit 6 by setting the manufacturing code uniquely corresponding to the central air conditioning unit 6 to follow the central air conditioning unit 6 and storing the manufacturing code in the cloud 1, so that the real-time updating and correction of the twin model 7 are possible.
The twin model 7 synchronizes real-time data of the entity machines of the central air conditioning unit 6, predicts failure in real time at the cloud 1, predicts failure reasons of the entity machines in advance, provides an effective solution in a targeted manner, and improves prediction efficiency and notification efficiency.
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 unit design parameters of the original model include structural design parameters, circulation system design parameters, electrical design parameters, and the like, which are all optimized and improved through multiple vibration tests, noise tests, enthalpy difference tests, electrical safety tests, EMC tests, and meet requirements of system capacity, structural strength, electrical safety, and EMC.
The critical component failure model is a life parameter of a critical component selected by the unit under a specific operation parameter, such as a life parameter of the compressor under a specific pressure, voltage and current; switching times of the electromagnetic valve under specific voltage and current; the service life value of the refrigerant pipeline under the specific pipeline pressure; the life of the screw under a specific moment and vibration, etc.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, the original model includes a plurality of models or capabilities corresponding to different central air conditioning units. The production code is uploaded to the cloud 1 to generate a twin model 7 according to the model or the capability of the central air conditioning unit 6 and the original model which is selected to be duplicated.
According to the fault monitoring method of the central air conditioning unit, various original models are uploaded to the cloud 1 according to the model or the capability, so that the central air conditioning unit 6 of different models or capabilities uses different original models, the pertinence and the accuracy of the original models are improved, and the accuracy of the twin model 7 is further improved.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, the manufacturing code is configured onto the central air conditioning unit 6 during the central air conditioning unit 6 manufacturing process 2 and follows the full life cycle of the central air conditioning unit 6 at all times.
The correction of the twin model 7 in the manufacturing process 2 includes the correction of the structural position and the connection parameters, the correction of the first refrigerant charge amount parameter, the correction of the line inspection operation high/low pressure parameter, the correction of the air tightness parameter, the correction of the electrical safety parameter, and the like.
According to the fault monitoring method of the central air conditioning unit, through correction of the structural position and the connection parameters in the production and manufacturing process 2, correction of the first refrigerant filling quantity parameters, correction of the line inspection operation high/low pressure parameters, correction of the air tightness parameters and correction of the electrical safety parameters, correction of the failure model of the key part is further caused, so that service life pre-judgment of the key part is more accurate, and further, fault pre-judgment is more accurate.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, the manufacturing code employs code of the MES system 8 and is uploaded to the cloud 1 through the MES system 8. That is, the MES system 8 collects the manufacturing codes at each manufacturing parameter mapping station and uploads each manufacturing parameter.
The fault monitoring method of the central air conditioner unit of the embodiment utilizes the intelligent production management system used by the existing production line to complete 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 that are not related to the MES system 8 and uploaded to the cloud 1 by other wired or wireless means. Such as a bus, the internet of things, the internet, etc.
For example, each screw fixation torque is uploaded to the twinning model 7 by the torque gun through the MES system 8; the installation deviation of sheet metal parts and the like can be collected through a special laser scanning equipment model, and the cloud 1 correction twin model 7 is uploaded through an MES system 8; before the box body of the central air conditioning unit 6 is sealed, the relative installation positions of key components such as copper pipe positions and the like are uploaded to the cloud 1 through system scanning for correction of the twin model 7.
In terms of system circulation, the first refrigerant filling amount, the high/low pressure of the line body detection system operation and the air tightness detection data are uploaded to the cloud 1 twin model 7 through the MES system 8, wherein some detection results are used as standard working condition parameters of the twin model 7 in later operation, and the service life assessment of key components in the central air conditioning unit 6 is corrected.
After the physical machine of the central air conditioning unit 6 is detected by the production line body, all the electrical safety parameters are recorded and uploaded; the electrical parameters of the central air conditioning unit 6 under the standard working conditions, such as peak current, instantaneous voltage and the like of the primary side and the secondary side, are uploaded to the cloud 1 to correct the twin model 7.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, and 8, the vibration coefficient is set, which is obtained according to an average value of the set values of the comprehensive simulation of the various road conditions and is greater than the average value.
Collecting the transportation time length in the transportation process 3; the transport parameter is equal to the product of the transport duration and the vibration coefficient, which characterizes the life loss of the transport parameter to the central air conditioning unit 6.
The collection and transportation duration can be obtained through an internet of things module arranged in the unit. Specifically, in the transportation process 3, the internet of things module collects the geographic position and reports the geographic position to the cloud end 1, when the reported geographic position continuously changes, the cloud end 1 accumulates and times the time when the geographic position continuously changes until the geographic position is not changed any more and the geographic position detection function is closed, and the time when all the geographic positions continuously changes is overlapped to obtain the transportation duration.
And uploading the transportation time to the cloud end 1, and calculating the product with the vibration coefficient to obtain transportation parameters. And the failure model of the key component in the twin model 7 is corrected, so that the judgment of judging whether the key component reaches failure early warning according to the operation parameters is more accurate when the central air conditioning unit 6 operates.
According to the fault monitoring method for the central air conditioner unit, continuous reporting of the geographic position is achieved through configuration of the Internet of things module, and the cloud end 1 judges whether the central air conditioner unit is in a transportation state or not according to the reported geographic position and calculates transportation duration in an accumulated mode; the cloud 1 determines the life loss of the central air conditioning unit 6 caused by the vibration loss caused by transportation according to the transportation time length, and the life loss is reflected to the critical component failure model through the correction of the twin model 7.
The product of the transportation duration and the vibration coefficient represents the loss of the vibration to the life of the physical machine. In order to ensure that the faults can be reported in advance before the faults occur, the vibration coefficient is comprehensively simulated and corrected to be higher than the average value according to various road conditions.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, the installation parameters include a second refrigerant charge amount, a line length.
The correlation between the total refrigerant filling amount of the system and the pipeline length and the key component failure model is configured in the twin model 7; the sum of the second charge in the installation process 4 and the first charge in the manufacturing process 2 and the length of the coolant lines affect the life of the critical components. During installation, the second refrigerant supplement filling quantity and the pipeline length are uploaded to the cloud 1 twin model 7 to correct the failure model of the key component, so that the failure early warning of the system where the central air conditioning unit 6 is located in the running state is more accurate, and further the failure early warning of the central air conditioning unit is more accurate.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 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 cloud 1 manufacturing code has no second refrigerant filling amount and no uploading of the pipeline length, the central air conditioning unit 6 is only allowed to operate in the debugging state and cannot operate in the user using state; when the twin model 7 under the corresponding manufacturing code receives the data of the second refrigerant filling amount and the pipeline length, the user operation mode is unlocked.
According to the central air conditioner fault early warning method, the user mode locking function is set to limit the after-sales department to finish cloud data in a standardized mode, so that a twin model 7 system of the central air conditioner 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 any more, and its correction of the twin model 7 is stopped. The acquisition of the geographic position is confirmed by reporting the position information through the internet of things module of the central air conditioning unit 6. For example, when the reported cell ID changes, it is characteristic that the crew unit is in transit. After the central air conditioning unit 6 is installed, the Internet of things module is enabled to switch the working mode through after-sale confirmation, and the acquisition and uploading of the geographic position are finished.
According to the fault monitoring method for the central air conditioning unit, after the installation is confirmed, the geographic position acquisition function is in a dormant or stop state, and the 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, 8, installation parameters in the installation process 4 are uploaded to the cloud 1 through the after-sales service system. The after-sales service system comprises an after-sales service system terminal 9 for inputting installation parameters and uploading them to the cloud 1 via the after-sales service system.
Specifically, the installation parameters are uploaded to the after-sales service system through the after-sales service system; and then, all the installation parameters of the after-sales service system are synchronized into a twin model through cloud-cloud docking. That is, the twin model 7 corresponding to the manufacturing code is invited by 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 central air conditioning unit 6 at the cloud 1 performs fault early warning, a fault early warning message is sent to an after-sales service system through communication between the cloud 1 and the cloud 1, or the fault early warning message is directly sent to a user controller or a bound intelligent mobile terminal, so that early repair or maintenance is reminded, and real fault is avoided.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, the operating parameters include a compressor pressure parameter, a compressor electrical parameter, a solenoid valve flow parameter, a solenoid valve switching number, an expansion valve electrical parameter, an expansion valve flow parameter, a four-way valve electrical parameter, a four-way valve switching number, a vibration parameter, a refrigerant high-low pressure parameter, an evaporation temperature, a condensation temperature, a superheat degree, a subcooling degree, and the like.
The above-mentioned operation parameters are obtained by the sensor arranged in the unit and the control information of the controller of the central air conditioner unit 6.
According to the fault monitoring method for the central air conditioner unit, the operation of the central air conditioner unit 6 is monitored under each operation parameter, once the abnormal parameter is found, analysis is carried out through the twin model 7 to obtain whether faults and tolerance time are about to occur, 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 sudden fault loss 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, fig. 8, 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 disposed 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, unit anomalies are primarily caused by anomalies in critical components. The key components include a compressor, an electromagnetic valve, a four-way valve and the like. The primary failure model of each critical component is input into the twinning model 7. When the key parts reach the natural service life or the damage caused by impact to the key parts under the extreme working condition, after-sales and users are reminded to replace the corresponding parts in advance.
For example, the switch life data of the solenoid valve may be determined during the model selection during the new product development phase. The actual operation data of the true machine are synchronized into the twin model 7 in real time, when the solenoid valve approaches to the service life threshold value, the possibility of fault occurrence exists, and then related operation parameters are focused, so that the accuracy of fault prediction is further improved.
Therefore, the failure model of the key parts affecting the operation of the unit is recorded in the twin model 7 of the central air conditioner unit 6, and the failure model of each key part is fitted through the life test and the temperature impact test result of each part.
In addition, when the critical component with failure early warning or failure is replaced, the parameters of the replaced critical component and the failure model are synchronized into the twin model 7, and the switching times and the service life of the critical component are recalculated.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, an organic group failure experience set function is configured in the twinning model 7, which includes operating parameter variables. When the failure of the key component is judged through the operation parameters and the failure model of the key component, a failure experience set function is called, the operation parameters in the existing operation state are brought into operation parameter variables, the failure of the key component is confirmed, and the occurrence accuracy of the failure is further confirmed.
The unit fault failure empirical set function in the central air conditioner unit fault monitoring method of the embodiment is a data set formed by summarizing known existing fault formation reasons, and mainly comprises operation parameters of the unit immediately before the fault occurs. When the failure model of the key component is about to be attenuated to a critical value, through the integrated analysis of the operation data of the current central air conditioning unit 6 and the comparison with the operation parameters in the failure data set, the problem cause can be positioned in time and the after-sale notification can be notified when the coincidence degree is higher.
The application also discloses a fault monitoring system of a central air conditioner unit, and referring to fig. 1, 2, 3, 4, 5, 6, 7 and 8, the fault monitoring system comprises a cloud end 1, a central air conditioner unit 6, a manufacturing parameter uploading unit, a transportation parameter uploading unit, an operation parameter uploading unit and a processing module.
The central air conditioning unit 6 is configured with a unique manufacturing code, and copies an original model to generate a twin model 7 under the manufacturing code and stores the twin model in the cloud 1; the original model comprises a plurality of unit design parameters and a plurality of critical component failure models which have correlation with the unit design parameters.
The manufacturing parameter uploading unit is arranged on a production and manufacturing line body of the central air conditioning unit 6 and is in communication connection with the cloud end 1, and the manufacturing parameters are acquired by coding the manufacturing codes and acquiring the manufacturing parameters, and the acquired manufacturing parameters are uploaded to the cloud end 1.
The transportation parameter uploading unit is arranged on the central air conditioning unit 6 and is in communication connection with the cloud end 1, and the transportation parameter is obtained and uploaded to the cloud end 1.
The installation parameter uploading unit is in communication connection with the cloud end 1, and an after-sales service department inputs the installation parameters and uploads the installation parameters 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 1, and obtains operation parameters to upload to the cloud 1.
The processing module is arranged at the cloud 1, and calls manufacturing parameters, transportation parameters and installation parameters to correct the twin model 7, and judges whether critical 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 the differences in the production and manufacturing processes 2, the transportation parameters with the differences in the transportation processes 3 and the installation parameters with the differences in the installation processes 4 of the central air conditioning unit 6, so that the twin model 7 of the central air conditioning unit 6 and a solid machine of the central air conditioning unit 6 have the identical unit parameters and operation parameters, and the statistics of operation wear generated by the operation state of the operation process 5 under the operation parameters is more accurate; and then the failure early warning of the key component judged by the key component failure model related to the unit parameter is more accurate, a reliable basis is provided for after-sales failure early warning, the accuracy of the failure early warning is improved, the maintenance period is shortened, the maintenance efficiency is further improved, and the maintenance cost is reduced.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, a set of unit failure experiences is configured in the twinning model 7, including operating parameter variables.
When judging that the critical component fault early warning exists through the operation parameters and the critical component failure model, the processing module calls a failure experience set of the unit fault, and confirms the critical component fault early warning when the operation parameters are brought into the operation parameter variables.
According to some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, 8, the manufacturing parameter uploading unit is an MES system 8; manufacturing a code encoded as 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 the position signal of the central air conditioning unit 6 at regular time and upload the position signal to the cloud 1; the processing module of the cloud 1 accumulates the duration of continuous movement according to the received position signals to obtain the transportation duration; the processing module is configured with vibration coefficients and calculates the product of the transport duration and the vibration coefficients, modifying the twin model 7.
The installation parameter uploading unit is an after-sales service system, which includes an after-sales service system terminal 9 for inputting installation parameters. And the operation parameters are uploaded to the cloud end 1 through the Internet of things module.
In some embodiments of the present application, referring to fig. 1, 2, 3, 4, 5, 6, 7, and 8, a central air conditioning unit 6 is provided, including 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 and is used for marking the twin model 7 corresponding to the central air conditioning unit 6 and uploading manufacturing parameters, transportation parameters, installation parameters and operation parameters.
The transportation parameter uploading module is in communication connection with the cloud end 1, and obtains transportation parameters to upload to the cloud end 1.
The operation parameter uploading unit is in communication connection with the cloud end 1, and obtains operation parameters to upload to the cloud end 1.
According to some embodiments of the application, the transportation parameter uploading module and the operation parameter uploading unit are shared as the internet of things module.
In the description of the above embodiments, particular features, structures, materials, or characteristics may be combined in any suitable manner in any one or more embodiments or examples.
The foregoing is merely illustrative of the present invention, and the present invention is not limited thereto, and any changes or substitutions easily contemplated by those skilled in the art within the scope of the present invention should be included in the scope of the present invention. Therefore, the protection scope of the invention is subject to the protection scope of the claims.
Claims (10)
1. The fault monitoring method for the central air conditioner unit is characterized by comprising the following steps of:
establishing an original model; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which have correlation with each unit design parameter;
the central air conditioning unit is configured with a unique manufacturing code when in production and manufacturing, and the manufacturing code is uploaded to a cloud for storage when being used for the first time, and a twin model which is copied with the original model is correspondingly stored; acquiring manufacturing parameters in the production and manufacturing process, uploading the manufacturing parameters to the cloud to correct the twin model corresponding to the manufacturing code;
Acquiring transportation parameters in the transportation process, uploading the transportation parameters to the cloud to correct the twin model corresponding to the manufacturing code;
acquiring installation parameters in an installation process, uploading the installation parameters to the cloud to correct the twin model corresponding to the manufacturing code;
and acquiring operation parameters in the operation process, uploading the operation parameters to the cloud end, synchronizing the operation parameters to the twin model corresponding to the manufacturing code, and judging whether critical component failure early warning exists according to the critical component failure model in the twin model.
2. The method for monitoring faults of a central air conditioner unit according to claim 1, wherein the original model is stored in a cloud;
storing a unique twin model under the manufacturing code;
the original models of the central air conditioner units with different models or capacities correspond to different unit design parameters and different critical component failure models; and under the manufacturing code, importing the corresponding original model according to the model or the capacity of the central air conditioning unit to generate the twin model.
3. The 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 picking and manufacturing parameter acquisition are carried out at each station through the MES system, and the acquired manufacturing parameters are uploaded to the cloud;
the manufacturing parameters comprise a structure connection parameter, a structure layout parameter, a first refrigerant filling amount, a system operation high/low pressure, air tightness and an electrical safety parameter.
4. The method for monitoring faults of a central air conditioner unit according to claim 1, wherein a vibration coefficient is set, and the vibration coefficient is obtained according to an average value of comprehensive simulation of a plurality of road conditions; the vibration coefficient is greater than the average value;
acquiring the transportation time length of the central air conditioning unit in the transportation process; and the product of the transportation time length and the vibration coefficient represents the service life loss of the central air conditioning unit, and the service life loss is uploaded to the cloud end to correct the twin model.
5. The method according to claim 4, wherein the installation parameters include a second refrigerant charge amount and a pipe length;
the cloud end sets a locking function for the central air conditioning unit corresponding to the manufacturing code; when the installation parameters are uploaded to the cloud to obtain the manufacturing codes, the cloud unlocks the user operation mode of the central air conditioning unit corresponding to the manufacturing codes.
6. The method for monitoring faults of a central air conditioning unit according to any of claims 1 to 5, further comprising:
configuring a set of unit fault failure experience set functions in the twin model, which include operating parameter variables;
when judging that the critical component fault early warning exists through the operation parameters and the critical component fault model, calling the unit fault failure experience set function, and confirming the critical component fault early warning when the operation parameters are brought into the operation parameter variables.
7. A central air conditioning unit fault monitoring system, comprising:
and (3) cloud end.
The central air conditioner unit is configured with a unique manufacturing code, and copies an original model under the manufacturing code to generate a twin model and stores the twin model in the cloud; the original model comprises a plurality of unit design parameters and a plurality of key component failure models which have correlation with the unit design parameters;
the manufacturing parameter uploading unit is arranged on a production and manufacturing line body of the central air conditioner unit and is in communication connection with the cloud end, and the acquired manufacturing parameters are uploaded to the cloud end by acquiring the manufacturing codes and the manufacturing parameters;
The transport parameter uploading unit is arranged on the central air conditioning unit and is in communication connection with the cloud end, and the transport parameter is obtained and uploaded to the cloud end;
the installation parameter uploading unit is in communication connection with the cloud end, and an after-sales service department inputs the installation parameters 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 to the cloud end;
and the processing module is arranged at the cloud end, invokes the manufacturing parameters, the transportation parameters and the installation parameters to correct the twin model, and judges whether critical component failure early warning exists according to the received operation parameters and the twin model.
8. The fault monitoring system of a central air conditioning unit according to claim 7, wherein,
configuring a set of unit fault failure experience set functions in the twin model, which include operating parameter variables;
when judging that the critical component fault early warning exists through the operation parameters and the critical component failure model, the processing module calls the unit fault failure experience set function, and confirms the critical component fault early warning when the operation parameters are brought into the operation parameter variables.
9. The fault monitoring system of a central air conditioner set according to claim 7 or 8, wherein,
the manufacturing parameter uploading unit is an MES system; the manufacturing code is a code of the MES system; the manufacturing parameters are uploaded 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; 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 length and the vibration coefficient, and corrects the twin model;
the installation parameter uploading unit is an after-sales service system and comprises an after-sales service system terminal for inputting the installation parameters;
and the operation parameters are uploaded to the cloud through the Internet of things module.
10. A central air conditioning unit comprising:
the unique manufacturing code is configured on the central air conditioner unit and is used for marking a twin model corresponding to the central air conditioner unit and uploading manufacturing parameters, transportation parameters, installation parameters and operation parameters to a cloud end to correct the twin model corresponding to the manufacturing code on the cloud end;
The transport parameter uploading module is in communication connection with the cloud end, and acquires the transport parameters to upload 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 to the cloud end.
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