CN115727947A - Vibration performance monitoring and early warning system of crushing and screening machine - Google Patents
Vibration performance monitoring and early warning system of crushing and screening machine Download PDFInfo
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- CN115727947A CN115727947A CN202211715662.8A CN202211715662A CN115727947A CN 115727947 A CN115727947 A CN 115727947A CN 202211715662 A CN202211715662 A CN 202211715662A CN 115727947 A CN115727947 A CN 115727947A
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Abstract
The invention discloses a vibration performance monitoring and early warning system of a crushing and screening machine, which comprises a vibration monitoring system, a wireless data acquisition system and a data analysis and processing system, wherein the vibration monitoring system is used for monitoring the vibration performance of the crushing and screening machine; the vibration monitoring system comprises a triaxial vibration sensor, and the triaxial vibration sensor is used for measuring the vibration of the crushing and screening machine in the vertical, horizontal and front-back directions in real time; the wireless data acquisition system comprises an AD acquisition module, an embedded main control module and a wireless transmission module; the data analysis and processing system is used for forming characteristic data capable of reflecting vibration performance on the acquired vibration data through time domain analysis, frequency domain analysis, power spectrum analysis, octave analysis and window function analysis, and establishing a vibration performance characteristic database, and the data analysis and processing system realizes monitoring and early warning on the vibration performance of the crushing and screening machine by establishing fault type data characteristics and comparing the fault type data characteristics with data in the vibration performance characteristic database.
Description
Technical Field
The invention relates to the technical field of monitoring of vibration performance of a crushing and screening machine, in particular to a monitoring and early warning system for vibration performance of a crushing and screening machine.
Background
The crushing and screening machine is mainly used for crushing and screening the sandstone aggregate, wherein the crusher produces granular stone by extruding and hammering the sandstone aggregate conveyed by the vibrating feeder; the screening machine adopts multilayer iron grid, screen cloth, orifice plate welding to a frame in, vibrates from top to bottom through the vibrating motor who attaches to on the frame, sieves into the stone material that is not unidimensional and the granularity is even with the stone. The working environment of the crushing and screening machine is extremely bad, dust and gravel permeate the whole working site, workers cannot monitor the vibration state of each working part of the crushing and screening machine on site in real time, and when the vibration performance of the machine is abnormal, not only stone produced produces mass quality accidents, but also equipment faults can be caused, and irreparable huge loss is caused.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a vibration performance monitoring and early warning system for a crushing and screening machine, which is used for monitoring the vibration performance of the whole machine and early warning faults.
The technical scheme adopted by the invention is as follows: the utility model provides a crushing and screening machine vibration performance monitoring early warning system which characterized in that: the system comprises a vibration monitoring system, a wireless data acquisition system and a data analysis processing system; the vibration monitoring system comprises a triaxial vibration sensor which is used for measuring the vibration sizes of the crushing and screening machine in the vertical, horizontal and front-back directions in real time; the wireless data acquisition system comprises an AD acquisition module, an embedded main control module and a wireless transmission module; the data analysis and processing system is used for forming characteristic data capable of reflecting vibration performance on the acquired vibration data through time domain analysis, frequency domain analysis, power spectrum analysis, octave analysis and window function analysis, and establishing a vibration performance characteristic database, and the data analysis and processing system realizes monitoring and early warning on the vibration performance of the crushing and screening machine by establishing fault type data characteristics and comparing the fault type data characteristics with data in the vibration performance characteristic database.
Preferably, the triaxial vibration sensor is connected to the magnetic base through a bolt and can be adsorbed to different parts of the crushing and screening machine to acquire vibration data of the whole machine.
Preferably, the time domain analysis method comprises: the system counts the maximum value and the minimum value of the acceleration of a certain part of the crushing and screening machine under the normal condition, and fits into a range interval to serve as the characteristic data of the part.
Preferably, the frequency domain analysis method comprises: the system counts acceleration peak values and corresponding frequencies of a certain part of the crushing and screening machine under normal conditions, and reasonable error intervals are combined on the basis to serve as characteristic data of the part.
Preferably, the power spectrum analysis method comprises the following steps: the system counts the acceleration signal power and the corresponding frequency of a certain part of the crushing and screening machine under the normal condition, and combines a reasonable error interval as the characteristic data of the part on the basis.
Preferably, the octave analysis method comprises the following steps: the system counts the acceleration signal power and the corresponding frequency band of a certain part of the crushing and screening machine under the normal condition, and combines a reasonable error interval as the characteristic data of the part on the basis.
Preferably, the window function analysis method includes: the system counts the vibration acceleration peak value and the corresponding frequency of a certain part of the crushing and screening machine under the normal condition, and combines a reasonable error interval as the characteristic data of the part on the basis.
Preferably, the fault type data characteristics include:
structural loosening data characteristics: irregular vibration impact occurs in the acceleration signal, and the vibration impact amplitude exceeds a set value;
shell cracking characteristic data: the acceleration signal generates an interference signal with reduced vibration frequency and increased amplitude;
rotating shaft eccentricity characteristic data: generating a vibration interference signal with a fixed frequency by the vibration data, and carrying out order analysis on the vibration data to generate a regular first-order disturbance signal;
bearing wear characteristic data: the acceleration signal has regular vibration interference, several vibration interference signals with fixed frequency are generated on the frequency domain, and the acceleration value of the interference signal exceeds a set value.
Preferably, the data analysis processing system is provided with a human-computer interaction interface, the human-computer interaction interface has the functions of real-time vibration data display, online acquisition, data analysis, data management and an early warning system, and the early warning system comprises an audible and visual alarm and the specific function of a trigger host control system; when the vibration performance of the crushing and screening machine is abnormal, the early warning system compares the database, can perform upper limit warning, lower limit warning, area warning and trend warning according to the abnormal vibration quantity, and triggers the idling or stopping command of the crushing host control system when the vibration is higher than the set maximum standard.
The invention has the beneficial effects that: the system can monitor the real-time state of the vibration performance of each working part of the crushing and screening machine on line, and when the vibration performance of the crushing and screening machine is abnormal, the system can quickly monitor and take corresponding early warning measures, so that the stone produced by equipment is prevented from producing mass quality accidents and further expansion of equipment faults. The system has the characteristics of real-time vibration monitoring, wireless data transmission, synchronous data analysis, abnormal vibration early warning and the like.
Drawings
FIG. 1 is a system schematic of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in figure 1, the vibration performance monitoring and early warning system of the crushing and screening machine comprises a vibration monitoring system, a wireless data acquisition system and a data analysis and processing system, wherein the vibration monitoring system monitors vibration signals of the crushing and screening machine in real time, and the vibration signals are acquired by the wireless data acquisition system and then transmitted to the data analysis and processing system to be used for monitoring the vibration performance of the whole machine. The vibration monitoring system comprises a triaxial vibration sensor, an AD acquisition module, an embedded main control module and a wireless transmission module, and can be installed at different parts of the crushing and screening machine to acquire vibration data. The triaxial vibration sensor is nested in the shell, the bottom of the shell is reliably connected with the magnetic base, the vibration sensor is connected to the magnetic base through bolts and can measure the vibration of the crushing and screening machine in the vertical, horizontal and front-back directions in real time, and the vibration sensor has the characteristics of strong anti-interference capability, high sampling frequency and the like and can capture instantaneous vibration impact. AD acquisition module installs in the vibration sensor casing, and the output of vibration sensor is connected with AD acquisition module's input, and AD acquisition module samples the voltage signal of vibration sensor and the quantization code is binary digital signal so that data transmission. The embedded main control module is arranged in the shell of the vibration sensor and connected with the AD acquisition module, and the AD acquisition module is triggered by a pulse signal to convert an analog quantity signal reflecting vibration quantity into a digital quantity signal. The wireless sending module is arranged in the shell of the vibration sensor and sends the vibration data converted into digital signals by the AD acquisition module to the wireless data acquisition instrument through the internal wireless radio frequency device.
The wireless data acquisition system comprises a wireless receiving module, a wireless data acquisition instrument and a data transmission controller and is mainly used for acquiring vibration data. The wireless data acquisition instrument receives and stores the real-time data sent by the vibration monitoring system through the wireless receiving module. The data transmission controller is mainly responsible for uploading and issuing data between the wireless data acquisition instrument and the vibration monitoring system, and transmits the data of the wireless data acquisition instrument to the host controller of the crushing and screening machine in a network communication mode.
The data analysis processing system comprises a host controller, a data processing system, a human-computer interface and an early warning system. And the host controller is used for receiving the data transmitted by the wireless data acquisition system, analyzing the data, feeding back the data, and controlling the crushing and screening machine to idle or stop in parallel. The data processing system comprises online data analysis, data storage and database comparison. The online data analysis is used for analyzing the vibration data acquired in real time into characteristic data capable of reflecting vibration performance through functional modules such as a time domain, a frequency domain, a power spectrum, an amplitude spectrum, an octave, a window function and the like and storing the characteristic data. Establishing a database by using characteristic data representing faults of loosening of a crushing and screening machine structure, cracking of a shell, eccentricity of a rotating shaft, breakage of the rotating shaft, bearing abrasion and the like, wherein the system has a real-time database comparison function, and gives an alarm when the crushing and screening machine vibrates abnormally; the system can also perform functions of historical data management, data diagnosis, automatic reporting and the like. The early warning system comprises an audible and visual alarm and a specific function of a trigger host control system; when the vibration performance of the crushing and screening machine is abnormal, the early warning system compares the database, can perform upper limit warning, lower limit warning, area warning, trend warning and the like according to the abnormal vibration quantity, and triggers the idling or stopping command of the crushing host control system when the vibration is higher than the set maximum standard.
In this embodiment, the method for time domain analysis, frequency domain analysis, power spectrum analysis, octave analysis, and window function analysis includes:
time domain analysis: representing the change condition of the vibration acceleration along with time, and carrying out system statistics on the maximum value and the minimum value of the acceleration under the normal condition and fitting the maximum value and the minimum value into a range interval as the characteristic data of the part; and comparing the vibration data acquired in real time with the characteristic data, and if the vibration exceeds a normal range and exceeds the frequency and amplitude of the range, and if the vibration exceeds a threshold value specified by the system, triggering the protection function of the crushing host machine.
And (3) frequency domain analysis: representing the distribution condition of the vibration acceleration along with the frequency, taking an acceleration peak value and the corresponding frequency thereof under the normal condition by the system, and giving a certain error interval as characteristic data of the part by the system according to an empirical formula on the basis; and comparing the vibration data acquired in real time with the characteristic data, and triggering a protection function of the crushing host if the vibration exceeds a normal range.
And (3) power spectrum analysis: the characteristic is the signal power in a unit frequency band, namely the distribution condition of the signal power in a frequency domain, the system counts the acceleration signal power and the corresponding frequency under the normal condition, and a certain error interval is given as the characteristic data of the part according to an empirical formula on the basis; and comparing the vibration data acquired in real time with the characteristic data, and triggering a protection function of the crushing host if the vibration exceeds a normal range.
And (3) octave analysis: dividing the discrete spectrum into frequency bands through octave analysis, respectively calculating the power spectrum in each frequency band, and summarizing to obtain the data, wherein the acceleration signal power and the corresponding frequency band under the normal condition are counted by a system, and a certain error interval is given as the characteristic data of the part according to an empirical formula on the basis; and comparing the vibration data acquired in real time with the characteristic data, and triggering a protection function of the crushing host if the vibration exceeds a normal range.
Window function analysis: the system cuts the acquired vibration signals by adopting different interception functions so as to reduce the energy leakage of the frequency spectrum and enable the signals to be closer to a real frequency spectrum; then, counting the vibration acceleration peak value and the corresponding frequency under the normal condition, and giving a certain error interval as the characteristic data of the part according to an empirical formula on the basis; and comparing the vibration data acquired in real time with the characteristic data, and triggering a protection function of the crushing host if the vibration exceeds a normal range.
In this embodiment, the fault feature data identification method includes:
structural loosening data characteristics: the acceleration signal that the system gathered appears irregular vibration and strikes to vibration impact amplitude is great.
Shell cracking characteristic data: the acceleration collected by the system generates an interference signal with reduced vibration frequency and larger amplitude, and the amplitude of the signal is larger along with the larger cracking degree.
Rotating shaft eccentricity characteristic data: the vibration data can generate a first-order vibration interference signal with fixed frequency, the acceleration value of the interference depends on the rotating speed and the eccentric amount of the rotating shaft, and the vibration data is subjected to order analysis to generate a regular first-order disturbance signal.
Rotating shaft cracking characteristic data: the acceleration signal generates a vibration signal larger than a normal value, and is accompanied by larger noise, and a multi-order disturbance signal is generated in order analysis.
Bearing wear characteristic data: in the operation process of the machine, the vibration signal deviation is generated due to the change of the axis position, the acceleration signal generates the interference of regular vibration, a plurality of vibration interference signals with fixed frequency can be generated in the frequency domain, and the interference acceleration value is large.
The data analysis processing system realizes the monitoring and early warning of the vibration performance of the crushing and screening machine by establishing fault type data characteristics and comparing the fault type data characteristics with data in a vibration performance characteristic database.
By adopting the scheme, the system can monitor the real-time state of the vibration performance of each working component of the crushing and screening machine on line, and when the vibration performance of the crushing and screening machine is abnormal, the system can quickly monitor and take corresponding early warning measures, so that stone produced by equipment is prevented from producing mass quality accidents and further expansion of equipment faults. The system has the characteristics of real-time vibration monitoring, wireless data transmission, synchronous data analysis, abnormal vibration early warning and the like.
Claims (9)
1. The utility model provides a crushing and screening machine vibration performance monitoring and early warning system which characterized in that: the system comprises a vibration monitoring system, a wireless data acquisition system and a data analysis processing system; the vibration monitoring system comprises a triaxial vibration sensor, and the triaxial vibration sensor is used for measuring the vibration of the crushing and screening machine in the vertical, horizontal and front-back directions in real time; the wireless data acquisition system comprises an AD acquisition module, an embedded main control module and a wireless transmission module; the data analysis and processing system is used for forming characteristic data capable of reflecting vibration performance on the acquired vibration data through time domain analysis, frequency domain analysis, power spectrum analysis, octave analysis and window function analysis, and establishing a vibration performance characteristic database, and the data analysis and processing system realizes monitoring and early warning on the vibration performance of the crushing and screening machine by establishing fault type data characteristics and comparing the fault type data characteristics with data in the vibration performance characteristic database.
2. The system of claim 1, wherein the system comprises: the triaxial vibration sensor is connected to the magnetic base through a bolt and can be adsorbed to different parts of the crushing and screening machine to acquire vibration data of the whole machine.
3. The system of claim 1, wherein the system comprises: the time domain analysis method comprises the following steps: the system counts the maximum value and the minimum value of the acceleration of a certain part of the crushing and screening machine under the normal condition, and fits into a range interval to serve as the characteristic data of the part.
4. The system of claim 1, wherein the system is configured to monitor and pre-warn the vibratory performance of the crushing and screening machine: the frequency domain analysis method comprises the following steps: the system counts acceleration peak values and corresponding frequencies of a certain part of the crushing and screening machine under normal conditions, and reasonable error intervals are combined on the basis to serve as characteristic data of the part.
5. The system of claim 1, wherein the system comprises: the power spectrum analysis method comprises the following steps: the system counts the acceleration signal power and the corresponding frequency of a certain part of the crushing and screening machine under the normal condition, and combines a reasonable error interval as the characteristic data of the part on the basis.
6. The system of claim 1, wherein the system is configured to monitor and pre-warn the vibratory performance of the crushing and screening machine: the octave analysis method comprises the following steps: the system counts the acceleration signal power and the corresponding frequency band of a certain part of the crushing and screening machine under the normal condition, and combines a reasonable error interval as the characteristic data of the part on the basis.
7. The system of claim 1, wherein the system comprises: the window function analysis method comprises the following steps: the system counts the vibration acceleration peak value and the corresponding frequency of a certain part of the crushing and screening machine under the normal condition, and combines a reasonable error interval as the characteristic data of the part on the basis.
8. The system of claim 1, wherein the system comprises: the fault type data characteristics comprise:
structural loosening data characteristics: irregular vibration impact occurs in the acceleration signal, and the vibration impact amplitude exceeds a set value;
shell cracking characteristic data: the acceleration signal generates an interference signal with reduced vibration frequency and increased amplitude;
rotating shaft eccentricity characteristic data: generating a vibration interference signal with a fixed frequency by the vibration data, and carrying out order analysis on the vibration data to generate a regular first-order disturbance signal;
bearing wear characteristic data: the acceleration signal has regular vibration interference, several vibration interference signals with fixed frequency are generated on the frequency domain, and the acceleration value of the interference signal exceeds a set value.
9. The system of claim 1, wherein the system is configured to monitor and pre-warn the vibratory performance of the crushing and screening machine: the data analysis and processing system is provided with a human-computer interaction interface, the functions of the human-computer interaction interface comprise real-time vibration data display, online acquisition, data analysis, data management and an early warning system, and the early warning system comprises an audible and visual alarm and the specific function of a trigger host control system; when the vibration performance of the crushing and screening machine is abnormal, the early warning system compares the database, can perform upper limit warning, lower limit warning, area warning and trend warning according to the abnormal vibration quantity, and triggers the idling or stopping command of the crushing host control system when the vibration is higher than the set maximum standard.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116489184A (en) * | 2023-03-27 | 2023-07-25 | 曲靖阳光新能源股份有限公司 | Silicon material crushing screening machine monitoring system based on wireless transmission |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116489184A (en) * | 2023-03-27 | 2023-07-25 | 曲靖阳光新能源股份有限公司 | Silicon material crushing screening machine monitoring system based on wireless transmission |
| CN116489184B (en) * | 2023-03-27 | 2024-02-27 | 曲靖阳光新能源股份有限公司 | Silicon material crushing screening machine monitoring system based on wireless transmission |
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