CN115824687A - Equipment fault early warning method, device, equipment and storage medium - Google Patents
Equipment fault early warning method, device, equipment and storage medium Download PDFInfo
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- CN115824687A CN115824687A CN202211636810.7A CN202211636810A CN115824687A CN 115824687 A CN115824687 A CN 115824687A CN 202211636810 A CN202211636810 A CN 202211636810A CN 115824687 A CN115824687 A CN 115824687A
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Abstract
The invention provides a method, a device, equipment and a storage medium for early warning equipment faults, wherein the method comprises the following steps: collecting real-time vibration data of equipment to be tested; triggering an equipment fault early warning notice when the real-time vibration data are judged to meet the preset early warning condition; and the tolerance parameter of the early warning condition is determined based on historical vibration data of the equipment to be tested in a normal working state. The invention can carry out fault early warning in advance before equipment fails, thereby enabling operation and maintenance personnel to check and maintain in time and avoiding the loss caused by the unplanned shutdown of an enterprise due to equipment failure.
Description
Technical Field
The invention relates to the technical field of data monitoring, in particular to a method, a device, equipment and a storage medium for early warning of equipment faults.
Background
In the technology of fault monitoring of mechanical equipment, the fault of mechanical equipment is mainly discovered through two ways: one is to make a routing inspection plan for regular routing inspection; and the other method is to obtain the equipment state and fault parameters through an equipment monitoring system. The equipment failure discovered through the two methods usually occurs after the fact, that is, the equipment failure can be monitored and discovered after the failure occurs, so that the enterprise is caused to stop unexpectedly and suffers from loss.
Disclosure of Invention
The invention aims to provide a method, a device, equipment and a storage medium for early warning of equipment faults, which aim to solve the technical problems and can carry out early warning before the equipment faults so as to avoid the loss caused by unplanned shutdown of an enterprise due to the equipment faults.
In order to solve the technical problem, the invention provides an equipment fault early warning method, which comprises the following steps:
collecting real-time vibration data of equipment to be tested;
triggering an equipment fault early warning notice when the real-time vibration data are judged to meet the preset early warning condition; and the tolerance parameter of the early warning condition is determined based on historical vibration data of the equipment to be tested in a normal working state.
Further, the determining that the real-time vibration data meets a preset early warning condition includes:
recording primary equipment vibration abnormity when the real-time vibration data exceeds a data abnormity threshold value defined by tolerance parameters of the early warning condition;
and when the accumulated and recorded abnormal vibration times of the equipment are larger than a first time threshold corresponding to the abnormal data threshold, judging that the real-time vibration data meet the early warning condition.
Further, the determining that the real-time vibration data meets a preset early warning condition further includes:
and when the accumulated and recorded abnormal vibration frequency of the equipment in a preset time period is greater than a second frequency threshold corresponding to the abnormal data threshold, judging that the real-time vibration data meets the early warning condition.
Furthermore, the real-time vibration data of the equipment to be tested is acquired by adopting a three-axis sensor; when the real-time vibration data are judged to meet the preset early warning conditions, equipment fault early warning notification is triggered, and the method comprises the following steps:
and dividing the real-time vibration data into a plurality of dimensions, respectively judging whether preset early warning conditions are met, and triggering equipment fault early warning notification when the real-time vibration data of any dimension meets the preset early warning conditions.
Further, the determining method of the tolerance parameter of the early warning condition includes:
acquiring historical vibration data of the equipment to be tested in a normal working state, and determining the maximum value, the minimum value and the average value of the historical vibration data;
and determining tolerance parameters of the early warning conditions based on the maximum value, the minimum value and the average value of the historical vibration data.
Further, the device fault early warning notification includes at least one of a system notification mode, an APP push notification mode, and a short message notification mode.
Further, after the triggering of the device malfunction early warning notification, the method further includes:
and determining an abnormal type corresponding to the real-time vibration data when the real-time vibration data meet a preset early warning condition, and generating a maintenance work order corresponding to the abnormal type.
The invention also provides an equipment fault early warning device, which comprises:
the data acquisition module is used for acquiring real-time vibration data of the equipment to be detected;
the fault early warning module is used for triggering equipment fault early warning notification when the real-time vibration data are judged to meet the preset early warning conditions; and determining tolerance parameters of the early warning conditions based on historical vibration data of the equipment to be tested in a normal working state.
The invention also provides terminal equipment which comprises a processor and a memory stored with a computer program, wherein the processor is used for realizing any equipment fault early warning method when executing the computer program.
The present invention also provides a non-transitory computer readable storage medium having stored thereon a computer program which, when executed by a processor, implements any one of the above-described method of device fault warning.
Compared with the prior art, the invention has the following beneficial effects:
the invention provides a method, a device, equipment and a storage medium for early warning equipment faults, wherein the method comprises the following steps: collecting real-time vibration data of equipment to be tested; triggering an equipment fault early warning notice when the real-time vibration data are judged to meet the preset early warning condition; and determining tolerance parameters of the early warning conditions based on historical vibration data of the equipment to be tested in a normal working state. The invention can carry out fault early warning in advance before equipment fails, thereby enabling operation and maintenance personnel to check and maintain in time and avoiding the loss caused by the unplanned shutdown of an enterprise due to equipment failure.
Drawings
FIG. 1 is a schematic flow chart of a method for early warning of equipment failure according to the present invention;
FIG. 2 is a second schematic flow chart of the method for warning equipment failure according to the present invention;
fig. 3 is a schematic structural diagram of the device failure early warning apparatus provided by the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be 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.
Referring to fig. 1, an embodiment of the present invention provides an apparatus fault early warning method, which may include:
s1, collecting real-time vibration data of equipment to be tested;
s2, when the real-time vibration data are judged to meet the preset early warning conditions, triggering equipment fault early warning notification; and the tolerance parameter of the early warning condition is determined based on historical vibration data of the equipment to be tested in a normal working state.
It should be noted that the tolerance parameter of the early warning condition can be set in advance according to the historical vibration data of the device to be detected in the normal working state, wherein the early warning condition can include various abnormal types, and abnormal early warning is performed from various angles, so that the accuracy of early warning is improved. When the real-time vibration data are compared and judged to meet the set early warning conditions according to the tolerance parameters, equipment fault early warning notification is triggered, so that operation and maintenance personnel can find equipment abnormity in time and make corresponding maintenance and repair plans in advance. Because the operation and maintenance personnel are reminded to overhaul and maintain before the equipment fails, the loss caused by the unplanned shutdown of the enterprise due to the equipment failure is effectively avoided.
In this embodiment of the present invention, further, the determining that the real-time vibration data meets a preset early warning condition includes:
recording primary equipment vibration abnormity when the real-time vibration data exceeds a data abnormity threshold value defined by tolerance parameters of the early warning condition;
and when the accumulated and recorded abnormal vibration times of the equipment are larger than a first time threshold corresponding to the abnormal data threshold, judging that the real-time vibration data meet the early warning condition.
It should be noted that a plurality of data anomaly thresholds may be set, and each data anomaly threshold corresponds to one anomaly tolerance number. And recording equipment vibration abnormity once when the monitored real-time vibration data exceeds a data abnormity threshold value once, and judging that fault early warning is needed when the accumulated abnormal times of the equipment vibration are larger than the corresponding times threshold value.
In this embodiment of the present invention, further, the determining that the real-time vibration data meets a preset early warning condition further includes:
and when the accumulated and recorded abnormal vibration frequency of the equipment in a preset time period is greater than a second frequency threshold corresponding to the abnormal data threshold, judging that the real-time vibration data meets the early warning condition.
It should be noted that, for the judgment of the abnormal vibration frequency of the equipment, the judgment of the cumulative record frequency in the previous embodiment is not related to time, and the warning is given when the cumulative record frequency reaches the corresponding frequency threshold; further, in the embodiment of the present invention, it may be set that the warning is triggered when a corresponding number threshold is reached within a certain time range, for example, the number of times of abnormal vibration of the device reaches 3 times within a week. The accumulated abnormal vibration frequency of the equipment may be set to zero after the maintenance personnel performs maintenance or service.
In the embodiment of the present invention, further, the real-time vibration data of the device to be tested is acquired by using a three-axis sensor; when judging that the real-time vibration data meet the preset early warning conditions, triggering equipment fault early warning notification, comprising:
and dividing the real-time vibration data into a plurality of dimensions, respectively judging whether preset early warning conditions are met, and triggering equipment fault early warning notification when the real-time vibration data of any dimension meets the preset early warning conditions.
It should be noted that the real-time vibration data may be divided into data of multiple dimensions, the early warning condition of the real-time vibration data of each dimension is determined, and when the real-time vibration data of any dimension meets the preset early warning condition, the device fault early warning notification is triggered. By the method, data monitoring can be refined, and the judgment precision of equipment data early warning is further improved.
In the embodiment of the present invention, further, the determining manner of the tolerance parameter of the warning condition includes:
acquiring historical vibration data of the equipment to be tested in a normal working state, and determining the maximum value, the minimum value and the average value of the historical vibration data;
and determining tolerance parameters of the early warning conditions based on the maximum value, the minimum value and the average value of the historical vibration data.
It should be noted that the maximum value, the minimum value and the average value of the data of each dimension can be obtained according to the historical vibration data of the device to be measured in the normal working state, and the corresponding data tolerance value can be determined according to the deviation degree of the maximum value and the minimum value from the average value, and is used as a critical value for judging whether the early warning condition is met.
In the embodiment of the present invention, the device fault early warning notification further includes at least one of a system notification manner, an APP push notification manner, and a short message notification manner.
It should be noted that, multiple notification manners may be set, and different notification manners are triggered correspondingly according to different types of abnormal conditions of the device.
In this embodiment of the present invention, further, after the triggering device failure early warning notification, the method further includes:
and determining an abnormal type corresponding to the real-time vibration data when the real-time vibration data meet a preset early warning condition, and generating a maintenance work order corresponding to the abnormal type.
It should be noted that, after triggering the device fault early warning, a corresponding maintenance work order may be generated according to the current abnormal type, and sent to the corresponding operation and maintenance personnel terminal, so that the corresponding operation and maintenance personnel responds to the maintenance work order and performs maintenance operation on the device.
Based on the above scheme, in order to better understand the device fault early warning method provided by the embodiment of the present invention, the following detailed description is provided:
aiming at the technical problems in the background art, the embodiment of the invention aims to perform predictive maintenance monitoring on mechanical machine tool equipment, discover equipment problems in advance and early warn by analyzing monitoring data in real time so that operation and maintenance personnel can check and maintain in time. The main implementation means comprises:
1. collecting normal vibration data of equipment: through the installation of the three-axis vibration sensor, normal vibration data of the equipment are collected, and the data are transmitted to the monitoring platform to be stored.
2. Forming equipment health vibration data: and forming a healthy vibration data model through analyzing the normal vibration data.
3. Judging and early warning abnormal vibration data of the equipment: and comparing the acquired real-time vibration data with the healthy vibration data model, and giving an early warning to abnormal data beyond the tolerance range according to user definition.
Referring to fig. 2, the embodiment of the present invention can be implemented by the following steps:
1. and (3) confirming a monitored object:
equipment needed to monitor vibration conditions is identified.
2. Installing a collecting sensor:
the sensor is installed according to the specific condition of the equipment, the installation principle is that the operation of the machine is not influenced, the structure of the machine is not damaged, and the installation mode comprises punching, pasting and the like.
3. Information acquisition:
three-axis vibration data are acquired by using a three-axis sensor (XYZ axis) during normal work, the data are transmitted to a communication gateway through a communication interface (including but not limited to RS232 and RS485 interfaces), and the communication gateway uploads the data to an Internet of things platform. In order to build a reliable health data model, it is usually necessary to collect data over three days (data collection is performed at preset collection intervals).
4. Forming equipment health working data:
XYZ triaxial data acquired by the sensor each time are respectively stored in different fields of a database, parameters such as a maximum value, a minimum value and an average value of each dimension are analyzed and used as a basis for setting an amplitude range when the equipment works healthily.
5. Early warning definition:
the platform can be set with real-time monitoring data alarm tolerance, monitoring data of which dimension, early warning after abnormal data for a plurality of times, early warning of abnormal data for a plurality of times within a certain time, early warning modes (including system notification, weChat, short message and the like), whether a work order is generated and the like.
6. Monitoring the state of the equipment in real time:
the sensor monitors the state of the equipment in real time, and when the difference between the acquired data and the health working data exceeds the definition range of the previous step, the system automatically triggers early warning.
7. Generating a maintenance/warranty work order:
the system can be interfaced with an equipment management system (or any related business system), and a maintenance/service work order can be automatically generated in the equipment management system (or any related business system) when early warning is given.
It should be noted that the features of the embodiments of the present invention include:
1. the health condition of the equipment is monitored in a predictive maintenance mode, and the occurrence of equipment problems is early warned.
2. And forming equipment health working data: XYZ triaxial data acquired by the sensor are respectively stored in different fields of the database to form a device health working data range.
3. And (3) self-defined equipment abnormity early warning: the range and mode of early warning can be defined in detail, including warning tolerance, monitoring dimension, early warning condition, early warning mode, etc.
4. A maintenance/warranty work order may be automatically generated: can be butted with systems such as equipment management and the like to automatically generate a maintenance work order.
It should be noted that the above method or flow embodiment is described as a series of acts or combinations for simplicity, but those skilled in the art should understand that the present invention is not limited by the described acts or sequences, as some steps may be performed in other sequences or simultaneously according to the present invention. Further, those skilled in the art will appreciate that the embodiments described in the specification are exemplary embodiments and that no single embodiment is necessarily required by the inventive embodiments.
Referring to fig. 3, an embodiment of the present invention further provides an apparatus failure early warning device, including:
the data acquisition module 1 is used for acquiring real-time vibration data of the equipment to be tested;
the fault early warning module 2 is used for triggering equipment fault early warning notification when the real-time vibration data are judged to meet the preset early warning conditions; and the tolerance parameter of the early warning condition is determined based on historical vibration data of the equipment to be tested in a normal working state.
Further, the fault pre-warning module 2 is specifically configured to:
recording primary equipment vibration abnormity when the real-time vibration data exceeds a data abnormity threshold value defined by tolerance parameters of the early warning condition;
and when the accumulated and recorded abnormal vibration times of the equipment are larger than a first time threshold corresponding to the abnormal data threshold, judging that the real-time vibration data meet the early warning condition.
Further, the fault pre-warning module 2 is specifically configured to:
and when the accumulated and recorded abnormal vibration frequency of the equipment in a preset time period is greater than a second frequency threshold corresponding to the abnormal data threshold, judging that the real-time vibration data meets the early warning condition.
Further, the real-time vibration data of the equipment to be tested is acquired by adopting a three-axis sensor; the fault early warning module 2 is specifically configured to:
and dividing the real-time vibration data into a plurality of dimensions, respectively judging whether preset early warning conditions are met, and triggering equipment fault early warning notification when the real-time vibration data of any dimension meets the preset early warning conditions.
Further, the determining method of the tolerance parameter of the early warning condition includes:
acquiring historical vibration data of the equipment to be tested in a normal working state, and determining the maximum value, the minimum value and the average value of the historical vibration data;
and determining tolerance parameters of the early warning conditions based on the maximum value, the minimum value and the average value of the historical vibration data.
Further, the device fault early warning notification includes at least one of a system notification mode, an APP push notification mode, and a short message notification mode.
Further, the device fault early warning apparatus further includes a work order generation module, which is configured to:
and determining an abnormal type corresponding to the real-time vibration data when the real-time vibration data meet a preset early warning condition, and generating a maintenance work order corresponding to the abnormal type.
It can be understood that the above apparatus item embodiments correspond to the method item embodiments of the present invention, and the device fault early warning apparatus provided in the embodiments of the present invention can implement the device fault early warning method provided in any one of the method item embodiments of the present invention.
The present invention also provides a non-transitory computer-readable storage medium having stored thereon a computer program which, when executed by a processor, implements any of the device failure warning methods described herein.
It should be noted that the above-described device embodiments are merely illustrative, where the units described as separate parts may or may not be physically separate, and the parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on multiple network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the solution of the present embodiment. In addition, in the drawings of the embodiment of the apparatus provided by the present invention, the connection relationship between the modules indicates that there is a communication connection between them, and may be specifically implemented as one or more communication buses or signal lines. One of ordinary skill in the art can understand and implement it without inventive effort.
It can be clearly understood by those skilled in the art that, for convenience and brevity, the specific working process of the apparatus described above may refer to the corresponding process in the foregoing method embodiment, and is not described herein again.
The terminal device may be a desktop computer, a notebook, a palm computer, a cloud server, or other computing devices. The terminal device may include, but is not limited to, a processor, a memory.
The Processor may be a Central Processing Unit (CPU), other general purpose Processor, a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), an off-the-shelf Programmable Gate Array (FPGA) or other Programmable logic device, discrete Gate or transistor logic, discrete hardware components, etc. The general-purpose processor may be a microprocessor or the processor may be any conventional processor or the like, which is the control center of the terminal device and connects the various parts of the whole terminal device using various interfaces and lines.
The memory may be used to store the computer program, and the processor may implement various functions of the terminal device by running or executing the computer program stored in the memory and calling data stored in the memory. The memory may mainly include a storage program area and a storage data area, wherein the storage program area may store an operating system, an application program required for at least one function, and the like; the storage data area may store data created according to the use of the mobile phone, and the like. In addition, the memory may include high speed random access memory, and may also include non-volatile memory, such as a hard disk, a memory, a plug-in hard disk, a Smart Media Card (SMC), a Secure Digital (SD) Card, a Flash memory Card (Flash Card), at least one magnetic disk storage device, a Flash memory device, or other volatile solid state storage device.
The storage medium is a computer-readable storage medium, in which the computer program is stored, which computer program, when being executed by a processor, is adapted to carry out the steps of the above-mentioned respective method embodiments. Wherein the computer program comprises computer program code, which may be in the form of source code, object code, an executable file or some intermediate form, etc. The computer-readable medium may include: any entity or device capable of carrying the computer program code, recording medium, usb disk, removable hard disk, magnetic disk, optical disk, computer Memory, read-Only Memory (ROM), random Access Memory (RAM), electrical carrier wave signals, telecommunications signals, software distribution medium, and the like. It should be noted that the computer readable medium may contain content that is subject to appropriate increase or decrease as required by legislation and patent practice in jurisdictions, for example, in some jurisdictions, computer readable media does not include electrical carrier signals and telecommunications signals as is required by legislation and patent practice.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.
Claims (10)
1. An equipment fault early warning method is characterized by comprising the following steps:
collecting real-time vibration data of equipment to be tested;
triggering an equipment fault early warning notice when the real-time vibration data are judged to meet the preset early warning condition; and the tolerance parameter of the early warning condition is determined based on historical vibration data of the equipment to be tested in a normal working state.
2. The equipment fault early warning method according to claim 1, wherein the judging that the real-time vibration data meets a preset early warning condition comprises:
recording primary equipment vibration abnormity when the real-time vibration data exceeds a data abnormity threshold value defined by tolerance parameters of the early warning condition;
and when the accumulated and recorded abnormal vibration times of the equipment are larger than a first time threshold corresponding to the abnormal data threshold, judging that the real-time vibration data meet the early warning condition.
3. The equipment fault early warning method according to claim 2, wherein the determining that the real-time vibration data meets a preset early warning condition further comprises:
and when the accumulated and recorded abnormal vibration frequency of the equipment in a preset time period is greater than a second frequency threshold corresponding to the abnormal data threshold, judging that the real-time vibration data meets the early warning condition.
4. The equipment fault early warning method according to claim 1, wherein the real-time vibration data of the equipment to be tested is acquired by a three-axis sensor; when judging that the real-time vibration data meet the preset early warning conditions, triggering equipment fault early warning notification, comprising:
and dividing the real-time vibration data into a plurality of dimensions, respectively judging whether preset early warning conditions are met, and triggering equipment fault early warning notification when the real-time vibration data of any dimension meets the preset early warning conditions.
5. The equipment fault early warning method according to claim 1, wherein the determination mode of the tolerance parameter of the early warning condition comprises the following steps:
acquiring historical vibration data of the equipment to be tested in a normal working state, and determining the maximum value, the minimum value and the average value of the historical vibration data;
and determining tolerance parameters of the early warning conditions based on the maximum value, the minimum value and the average value of the historical vibration data.
6. The equipment fault early warning method according to claim 1, wherein the equipment fault early warning notification comprises at least one of a system notification mode, an APP push notification mode and a short message notification mode.
7. The device malfunction alerting method according to any one of claims 1-6, further comprising, after the triggering of the device malfunction alerting notification:
and determining an abnormal type corresponding to the real-time vibration data when the real-time vibration data meet a preset early warning condition, and generating a maintenance work order corresponding to the abnormal type.
8. An equipment fault early warning device, comprising:
the data acquisition module is used for acquiring real-time vibration data of the equipment to be detected;
the fault early warning module is used for triggering equipment fault early warning notification when the real-time vibration data are judged to meet the preset early warning conditions; and determining tolerance parameters of the early warning conditions based on historical vibration data of the equipment to be tested in a normal working state.
9. A terminal device comprising a processor and a memory storing a computer program, wherein the processor implements the device failure warning method according to any one of claims 1 to 7 when executing the computer program.
10. A non-transitory computer-readable storage medium having stored thereon a computer program, wherein the computer program, when executed by a processor, implements the device failure warning method according to any one of claims 1 to 7.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
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| CN202211636810.7A CN115824687A (en) | 2022-12-16 | 2022-12-16 | Equipment fault early warning method, device, equipment and storage medium |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211636810.7A CN115824687A (en) | 2022-12-16 | 2022-12-16 | Equipment fault early warning method, device, equipment and storage medium |
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| CN115824687A true CN115824687A (en) | 2023-03-21 |
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| CN202211636810.7A Pending CN115824687A (en) | 2022-12-16 | 2022-12-16 | Equipment fault early warning method, device, equipment and storage medium |
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| CN (1) | CN115824687A (en) |
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