CN116679630A - Equipment safety monitoring system based on ultrasonic detection - Google Patents
Equipment safety monitoring system based on ultrasonic detection Download PDFInfo
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- CN116679630A CN116679630A CN202310559986.5A CN202310559986A CN116679630A CN 116679630 A CN116679630 A CN 116679630A CN 202310559986 A CN202310559986 A CN 202310559986A CN 116679630 A CN116679630 A CN 116679630A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/12—Analysing solids by measuring frequency or resonance of acoustic waves
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/023—Solids
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31088—Network communication between supervisor and cell, machine group
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Abstract
The invention discloses an equipment safety monitoring system based on ultrasonic detection, which comprises: the invention relates to the technical field of equipment safety, in particular to a data acquisition module, an abnormality identification module, a characteristic extraction module and a data analysis module. The equipment safety monitoring system based on ultrasonic detection performs analysis through ultrasonic monitoring and utilizing an algorithm, realizes real-time monitoring and early warning of equipment, can timely discover equipment faults and abnormal conditions, thereby avoiding equipment damage and accidents, improving production efficiency, reducing risks of production accidents, having the advantages of high precision, multi-parameter detection, real-time early warning and the like, simultaneously utilizing a fault analysis model, performing analysis early warning on the equipment, reducing the probability of occurrence of accidents, guaranteeing production safety, performing visual display on analysis results, providing decision support for equipment maintenance, greatly reducing investment of manpower and material resources, and further reducing the operation cost of enterprises.
Description
Technical Field
The invention relates to the technical field of equipment safety, in particular to an equipment safety monitoring system based on ultrasonic detection.
Background
With the continuous development of automation technology, more and more devices are used in industrial production, and the normal operation of the devices is important to ensure the production safety.
The traditional equipment monitoring method requires manual intervention, consumes time and labor, is difficult to realize high-precision monitoring and early warning, and has the advantages that the equipment failure rate in production is continuously increased due to various complex factors in the production process, the traditional equipment maintenance method requires detection and maintenance by professionals, and many equipment monitoring still depends on manual inspection and experience judgment, so that the time and labor are wasted, the problem cannot be eradicated, the equipment state monitoring is incomplete, particularly, some parts inside the equipment cannot be directly observed, and continuous monitoring and early warning of key equipment are difficult to realize.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides an equipment safety monitoring system based on ultrasonic detection, and solves the problems in the background art.
In order to achieve the above purpose, the invention is realized by the following technical scheme: an equipment safety monitoring system based on ultrasonic detection, comprising:
the data acquisition module is used for transmitting ultrasonic waves to the target equipment by utilizing the ultrasonic transmitter, acquiring reflected ultrasonic parameters by the ultrasonic receiver, wherein the ultrasonic parameters comprise frequency and power density, and simultaneously acquiring equipment data of the target equipment, the equipment data comprise the model, the position and the operation parameters of the target equipment, and the operation parameters comprise the natural frequency of each part in the target equipment, the monitoring frequency obtained by detection of the vibration sensor and the corresponding part codes;
the abnormality identification module judges whether the target equipment has an abnormal condition according to the ultrasonic parameters, generates an abnormal signal according to the abnormal condition, and then sends the abnormal signal to the feature extraction module;
the feature extraction module is used for comparing the monitoring frequency and the natural frequency of the target equipment with a preset threshold value after calculating, determining part codes of fault parts, and then determining the follow-up time in a pre-trained fault analysis model;
and the data analysis module is used for analyzing the equipment data of the target equipment and determining the part codes of the parts with faults.
Preferably, the specific comparison mode of the abnormal conditions is as follows:
AS1, taking a group of target devices AS an example, when the target devices are normally used, acquiring the frequency Ci of the target devices at intervals of preset time T, and simultaneously acquiring the power density G i of the target devices, wherein i=1, 2, & gt and n represent that the acquisition times are n times;
AS2, using the formulaObtaining a first bias evaluation value P1 of n frequencies, wherein Cp is an average value of the acquired n frequencies, and similarly, obtaining a second bias evaluation value P2 of n power densities;
AS3, then, periodically collecting the frequency C of the target equipment in the subsequent use state at intervals of preset time T m And power density G m M represents the frequency and the power density obtained by the mth acquisition under the subsequent use state of the target equipment, and |C is calculated m -Cp|and |G m -gp| is compared with P1 and P2, respectively, where Gp is the average of the n power densities acquired when the target device is in normal use;
if |C m -Cp| > P1 and |G m -any one of Gp| > P2 is established, and C is continuously acquired m+1 And G m+2 、C m+2 And G m+2 、....、C m+k And G m+k K is the acquisition frequency and power after the mth timeThe number of densities;
then |C m+1 -Cp|and |G m+1 -gp| is compared with P1 and P2 respectively, continuing to compare |c m+2 -Cp|and |G m+2 Gp| is compared to P1 and P2, respectively,.. m+k -Cp|and |G m+k -gp| is compared with P1 and P2, respectively;
when |C m+1 -Cp| > P1 and |G m Any one of the terms Gp > P2 holds true while C m+1 -Cp| > P1 and |G m -gp| > P2, any one of which holds true,.. m+1 -Cp| > P1 and |G m -gp| > P2, then concluding that the target device has an abnormal condition and generating an abnormal signal.
Preferably, the fault characteristic frequency is obtained by the following steps: and calculating the absolute value of the difference between the monitoring frequency and the natural frequency of the part, comparing the absolute value of the difference with a preset threshold value, and marking the group of monitoring frequencies as fault characteristic frequencies if the absolute value of the difference exceeds the preset threshold value.
Preferably, the data analysis module is further configured to determine a follow-up time in a pre-trained fault analysis model, where the follow-up time is determined in a manner that: when the fault analysis model is trained, the fixed values of fault characteristic frequencies of all parts in different time periods are recorded until the parts cannot support the safe operation stop record of the equipment, and then the duration from the time of corresponding fault characteristic frequency record to the time of stop record is obtained and is used as the continuous time.
Preferably, the specific analysis mode of the data analysis module is as follows:
BS1, taking a group of parts as an example, marks the monitoring frequency and the natural frequency as m and Y respectively;
BS2, obtaining a comparison value Z by z= |m-y|;
BS3, comparing Z with a preset threshold Z0, if Z is larger than Z0, judging that the group of parts have faults, generating an early warning signal, entering a step BS4, otherwise, repeating the steps BS1 to BS3 to perform fault analysis on other parts in the target equipment;
and BS4, acquiring the continuous time of the part under the current fault characteristic frequency in a pre-trained fault analysis model.
Preferably, the method further comprises: the early warning display module is used for displaying the model and the position of the target equipment with abnormal conditions, the coding and the continuous use time of the parts with the fault conditions, and simultaneously carrying out acousto-optic warning reminding through early warning signals.
Advantageous effects
The invention provides an equipment safety monitoring system based on ultrasonic detection. Compared with the prior art, the method has the following beneficial effects:
the invention realizes real-time monitoring and early warning of equipment by ultrasonic monitoring and analysis by utilizing an algorithm, and can discover equipment faults and abnormal conditions in time, thereby avoiding equipment damage and accidents, improving production efficiency, reducing the risk of production accidents, having the advantages of high precision, multi-parameter detection, real-time early warning and the like, simultaneously utilizing a fault analysis model, analyzing and early warning the equipment to reduce the occurrence probability of accidents, ensuring production safety, and carrying out visual display on analysis results, providing decision support for equipment overhaul, and greatly reducing the investment of manpower and material resources, thereby reducing the operation cost of enterprises.
Drawings
Fig. 1 is a system block diagram of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, the present invention provides a technical solution, an equipment safety monitoring system based on ultrasonic detection, as a first embodiment of the present invention, including:
the data acquisition module is used for transmitting ultrasonic waves to the target equipment by utilizing the ultrasonic transmitter, and acquiring reflected ultrasonic wave parameters including frequency and power density by utilizing the ultrasonic receiver, and the technology is not described in detail herein, equipment data of the target equipment are acquired, the equipment data comprise the model, the position and the operation parameters of the target equipment, and the operation parameters comprise the natural frequency of each part in the target equipment, the monitoring frequency obtained by detection of the vibration sensor and corresponding part codes;
the abnormality identification module judges whether the target equipment has an abnormal condition according to the ultrasonic parameters, generates an abnormal signal according to the abnormal condition, and then sends the abnormal signal to the feature extraction module, wherein the specific comparison mode is as follows:
AS1, taking a group of target devices AS an example, when the target devices are normally used, acquiring the frequency Ci of the target devices at intervals of preset time T, and simultaneously acquiring the power density G i of the target devices, wherein i=1, 2, & gt and n represent that the acquisition times are n times;
AS2, using the formulaObtaining a first bias evaluation value P1 of n frequencies, wherein Cp is an average value of the acquired n frequencies, and similarly, obtaining a second bias evaluation value P2 of n power densities;
AS3, then, periodically collecting the frequency C of the target equipment in the subsequent use state at intervals of preset time T m And power density G m M represents the frequency and the power density obtained by the mth acquisition under the subsequent use state of the target equipment, and |C is calculated m -Cp|and |G m -gp| is compared with P1 and P2, respectively, where Gp is the average of the n power densities acquired when the target device is in normal use;
if |C m -Cp| > P1 and |G m -any one of Gp| > P2 is established, and C is continuously acquired m+1 And G m+2 、C m+2 And G m+2 、....、C m+k And G m+k K is the number of times after the mth time the frequency and power density are acquired;
then |C m+1 -Cp|and |G m+1 -gp| is compared with P1 and P2 respectively, continuing to compare |c m+2 -Cp|and |G m+2 Gp| is compared to P1 and P2, respectively,.. m+k -Cp|and |G m+k -gp| is compared with P1 and P2, respectively;
when |C m+1 -Cp| > P1 and |G m Any one of the terms Gp > P2 holds true while C m+1 -Cp| > P1 and |G m -gp| > P2, any one of which holds true,.. m+1 -Cp| > P1 and |G m -if any of Gp > P2 is true, then concluding that the target device is in an abnormal condition and generating an abnormal signal;
if |C m -Cp| > P1 and |G m -Gp| > P2, then periodically acquiring the frequency C of the target device in the subsequent use state m+1 And power density G m+1 Repeating the step AS3 to compare again;
the feature extraction module is used for extracting the equipment data and the fault feature frequency of the target equipment according to the abnormal signal and sending the equipment data and the fault feature frequency to the data analysis module, and the fault feature frequency is obtained in the following way: calculating the absolute value of the difference between the monitoring frequency of the part and the natural frequency through a large number of experiments to monitor the monitoring frequency of the part, comparing the absolute value of the difference with a preset threshold value, and marking the group of monitoring frequencies as fault characteristic frequencies if the absolute value of the difference exceeds the preset threshold value;
the data analysis module is used for analyzing the equipment data of the target equipment and determining the part coding and the continuous time of the fault part, and the specific analysis mode is as follows:
BS1, taking a group of parts as an example, marks the monitoring frequency and the natural frequency as m and Y respectively;
BS2, obtaining a comparison value Z by z= |m-y|;
BS3, comparing Z with a preset threshold Z0, if Z is larger than Z0, judging that the group of parts have faults, generating an early warning signal, simultaneously entering steps BS4 and BS5, otherwise, repeating steps BS1 to BS3 to perform fault analysis on other parts in the target equipment;
BS4, acquiring the continuous time of the part under the current fault characteristic frequency in a pre-trained fault analysis model;
the subsequent time is determined in the following manner: when the fault analysis model is trained, recording fixed values of fault characteristic frequencies of all parts in different periods until the parts cannot support safe operation of equipment and stop recording when the equipment cannot produce qualified products, and then acquiring the duration from the time of recording the corresponding fault characteristic frequencies to the time of stopping recording as the continuous time;
the necessity of a follow-up time is exemplified:
firstly, when a product is produced by equipment, related maintenance personnel cannot maintain the equipment in time due to various factors such as long distance, and the like, meanwhile, the product needs to be produced in an urgent way, namely, the continuous use time of the equipment on the premise of safe use can be determined through the continuous time, the reputation of enterprises is prevented from being influenced due to the tiny faults of the equipment, and meanwhile, the safe use of the equipment can be ensured;
secondly, when a product is produced by the equipment, a large amount of processing raw materials exist in the equipment, related personnel need to clean the processing raw materials in the equipment before repairing parts in the equipment, and then the equipment can be repaired, and the raw materials can be continuously processed by determining the continuous use time of the equipment on the premise of safe use through the continuous use time, so that the storage amount of the processing raw materials in the equipment is reduced or the storage amount of the processing raw materials in the equipment is completely cleaned, and then the equipment is repaired, so that a large amount of cleaning time can be saved, and the production of the product is ensured;
BS5, obtaining the model, the position and the part coding and the continuous time of the target equipment and transmitting the model, the position and the part coding and the continuous time to an early warning display module;
the early warning display module is used for displaying the model and the position of the target equipment with abnormal conditions, and the coding and the continuous use time of parts with fault conditions, and simultaneously carrying out acousto-optic warning reminding through the early warning signals, so that relevant personnel are conveniently reminded to carry out processing.
The invention realizes real-time monitoring and early warning of equipment by ultrasonic monitoring and analysis by utilizing an algorithm, can timely find out abnormal conditions and faults of the equipment, thereby avoiding equipment damage and accidents, improving production efficiency, reducing the risk of production accidents, having the advantages of high precision, multi-parameter detection, real-time early warning and the like, simultaneously utilizing a fault analysis model, analyzing and early warning the equipment to reduce the occurrence probability of accidents, guaranteeing production safety, visually displaying analysis results, providing decision support for equipment maintenance, greatly reducing the investment of manpower and material resources and reducing the operation cost of enterprises;
the second embodiment of the present invention is different from the first embodiment in that the early warning display module in the first embodiment is replaced by an early warning push module, and the steps are replaced by BS5, and then the model, the position, the part codes and the duration of the target device are acquired and transmitted to the early warning push module;
the embodiment is that, further comprising: the early warning pushing module is used for editing the model, the position, the part codes and the follow-up time of the target equipment into text information according to the early warning signals, and sending the text information to related maintenance personnel in a mode of short messages, mails, telephones and the like, so that the related personnel are conveniently reminded to process, automatic management can be realized, the manual inspection times are reduced, and the cost and the management difficulty are reduced.
And all that is not described in detail in this specification is well known to those skilled in the art.
The foregoing describes one embodiment of the present invention in detail, but the disclosure is only a preferred embodiment of the present invention and should not be construed as limiting the scope of the invention. All equivalent changes and modifications within the scope of the present invention are intended to be covered by the present invention.
Claims (6)
1. Equipment safety monitoring system based on ultrasonic detection, characterized by comprising:
the data acquisition module is used for transmitting ultrasonic waves to the target equipment by utilizing the ultrasonic transmitter, acquiring reflected ultrasonic parameters by utilizing the ultrasonic receiver, transmitting the ultrasonic parameters to the anomaly identification module, and simultaneously acquiring equipment data of the target equipment, wherein the ultrasonic parameters comprise frequency and power density, the equipment data comprise the model, the position and the operation parameters of the target equipment, and the operation parameters comprise the natural frequency of each part in the target equipment, the monitoring frequency obtained by detection of the vibration sensor and the corresponding part codes;
the abnormality identification module is used for obtaining first bias evaluation values of n frequencies according to the frequency and the power density of the target equipment, obtaining second bias evaluation values of n power densities, calculating the frequency and the power density of the target equipment in a subsequent use state, comparing the calculated frequency and power density with the first bias evaluation values and the second bias evaluation values, generating an abnormality signal according to a comparison result, and then sending the abnormality signal to the feature extraction module;
the feature extraction module is used for extracting the equipment data and the fault feature frequency of the target equipment according to the abnormal signals and sending the equipment data and the fault feature frequency to the data analysis module;
and the data analysis module is used for calculating the monitoring frequency and the natural frequency of the target equipment, comparing the calculated monitoring frequency and the natural frequency with a preset threshold value and determining part codes of parts with faults.
2. The ultrasonic detection-based equipment safety monitoring system according to claim 1, wherein the specific comparison mode of the abnormal condition is:
AS1, selecting a group of target equipment, and acquiring the frequency Ci of the target equipment at intervals of preset time T when the target equipment is in normal use, and simultaneously acquiring the power density Gi, i=1, 2, and n of the target equipment, wherein the acquisition times are n times;
AS2, using the formulaObtaining a first bias evaluation value P1 of n frequencies, wherein Cp is an average value of the acquired n frequencies, and similarly, obtaining a second bias evaluation value P2 of n power densities;
AS3, then, periodically collecting the frequency C of the target equipment in the subsequent use state at intervals of preset time T m And power density G m M represents the frequency and the power density obtained by the mth acquisition under the subsequent use state of the target equipment, and |C is calculated m -Cp|and |G m -gp| is compared with P1 and P2, respectively, where Gp is the average of the n power densities acquired when the target device is in normal use;
if |C m -Cp| > P1 and |G m -any one of Gp| > P2 is established, and C is continuously acquired m+1 And G m+2 、C m+2 And G m+2 、....、C m+k And G m+k K is the number of times after the mth time the frequency and power density are acquired;
then |C m+1 -Cp|and |G m+1 -gp| is compared with P1 and P2 respectively, continuing to compare |c m+2 -Cp|and |G m+2 Gp| is compared to P1 and P2, respectively,.. m+k -Cp|and |G m+k -gp| is compared with P1 and P2, respectively;
when |C m+1 -Cp| > P1 and |G m Any one of the terms Gp > P2 holds true while C m+1 -Cp| > P1 and |G m -gp| > P2, any one of which holds true,.. m+1 -Cp| > P1 and |G m -gp| > P2, then concluding that the target device has an abnormal condition and generating an abnormal signal.
3. The ultrasonic detection-based device safety monitoring system of claim 1, wherein: the fault characteristic frequency is obtained in the following way: and calculating the absolute value of the difference between the monitoring frequency and the natural frequency of the part, comparing the absolute value of the difference with a preset threshold value, and marking the group of monitoring frequencies as fault characteristic frequencies if the absolute value of the difference exceeds the preset threshold value.
4. The ultrasonic detection-based device safety monitoring system of claim 1, wherein: the data analysis module is further used for determining the follow-up time in a pre-trained fault analysis model, and the follow-up time is determined in the following manner: when the fault analysis model is trained, the fixed values of fault characteristic frequencies of all parts in different time periods are recorded until the parts cannot support the safe operation stop record of the equipment, and then the duration from the time of corresponding fault characteristic frequency record to the time of stop record is obtained and is used as the continuous time.
5. The ultrasonic detection-based device security monitoring system of claim 4, wherein: the specific analysis mode of the data analysis module is as follows:
BS1, taking a group of parts as an example, marks the monitoring frequency and the natural frequency as m and Y respectively;
BS2, obtaining a comparison value Z by z= |m-y|;
BS3, comparing Z with a preset threshold Z0, if Z is larger than Z0, judging that the group of parts have faults, generating an early warning signal, entering a step BS4, otherwise, repeating the steps BS1 to BS3 to perform fault analysis on other parts in the target equipment;
and BS4, acquiring the continuous time of the part under the current fault characteristic frequency in a pre-trained fault analysis model.
6. The ultrasonic detection-based device security monitoring system of claim 1, further comprising: the early warning display module is used for displaying the model and the position of the target equipment with abnormal conditions, the coding and the continuous use time of the parts with the fault conditions, and simultaneously carrying out acousto-optic warning reminding through early warning signals.
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