CN117198102A - Large-scale equipment remote diagnosis and ECS training platform - Google Patents

Large-scale equipment remote diagnosis and ECS training platform Download PDF

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Publication number
CN117198102A
CN117198102A CN202311021415.2A CN202311021415A CN117198102A CN 117198102 A CN117198102 A CN 117198102A CN 202311021415 A CN202311021415 A CN 202311021415A CN 117198102 A CN117198102 A CN 117198102A
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assessment
module
unit
training
fault
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温伟军
邱远瞻
王勇
钟嘉鸣
饶日
林灿
林海生
欧阳军
吴灵东
林舜杨
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Shantou Cmport Group Co ltd
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Shantou Cmport Group Co ltd
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Priority to CN202311021415.2A priority Critical patent/CN117198102A/en
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Abstract

The invention discloses a remote diagnosis and ECS training platform for large equipment. It includes a simulation integrated system; a master control operating system connected with the simulation integrated system; the remote diagnosis system and the training and checking system are in butt joint with the simulation integrated system in the main control operation system, wherein the main control operation system comprises a main control cabinet and an operation table. The training and checking system comprises a grading training system and a comprehensive checking system, wherein the grading training system is used for setting an access simulation integrated system and an operation table in a central processing module of the main control cabinet. The beneficial effects of the invention are as follows: the invention adopts the simulation integrated system as the basis, the structure of the simulation integrated system is completely the same as that of the actual port operation equipment, an independent remote diagnosis system is configured in the simulation integrated system, and a set of training assessment system with completely the same function as that of the actual system is formed by combining the main control operation system and the training assessment system, so that an easy-to-use and practical service level lifting platform is provided for sustainable development of port production operation.

Description

Large-scale equipment remote diagnosis and ECS training platform
Technical Field
The invention relates to the technical field of port equipment operation and maintenance, in particular to a remote diagnosis and ECS training platform for large equipment.
Background
With the increase of global economy, the development of port logistics industry is rapidly developed. In modern maritime industry port handling equipment plays a vital role. The operational stability and efficiency of port handling equipment directly affects port cargo handling efficiency and customer satisfaction.
Port handling equipment is an important infrastructure in modern port handling operations, which often requires complex operations and coordination to accomplish accurate movement of cargo. In conventional port loading and unloading operations, operators must be trained and practiced for a long time to grasp the operation skills, and the safety and efficiency of the operation are often limited.
In order to solve these problems, a number of port shore bridge simulation systems based on computer technology have appeared in recent years. By simulating a real port scene, the system enables operators to practice and become familiar with the operation flow in the virtual environment, so that the safety and efficiency of operation are improved.
The existing port shore bridge simulation systems mostly adopt a simulation technology based on a two-dimensional plane, and the technology cannot truly simulate the motion and scene change of a three-dimensional space. Meanwhile, the existing system has certain defects in the aspects of operation efficiency, fault simulation, scene restoration and the like, and a port shore bridge simulation system with higher intellectualization and high efficiency is urgently needed.
Along with the continuous expansion of the production scale of the wharf, the operation intensity of equipment and the failure rate of the equipment are continuously improved, the processing time of the equipment failure is longer, and the soft failure of the module fittings causes the influence on the production efficiency of the harbor area.
The technical level of the technical part equipment support center personnel is uneven, and the principle of the container equipment electric control system is quite vivid, so that the technical part adheres to the traditional training of' a teacher takes a role and a helper to quickly improve the technical level of maintenance personnel. Because the training and practical operation of large-scale equipment are difficult, the risk is high, and the effect of adopting the traditional belt is not ideal.
Because of the problems in the continuous and stable operation of the port loading and unloading equipment and the requirements of personnel operation proficiency, I develop a technical scheme capable of effectively monitoring and feeding back the operation condition of the port loading and unloading equipment, maintaining the stable operation of the equipment and providing high-efficiency and accurate cultivation and establishment of technical personnel.
Disclosure of Invention
The invention aims to overcome the defects of the conventional port loading and unloading equipment in operation and the cultivation of related technicians, and provides a large equipment remote diagnosis and ECS training platform which can remotely diagnose and effectively cultivate and examine the corresponding operation and maintenance service level of the technicians.
In order to solve the technical problems, the invention adopts the following technical scheme:
a large-scale equipment remote diagnosis and ECS training platform comprises a simulation integrated system; a master control operating system connected with the simulation integrated system; and the remote diagnosis system is in butt joint with the simulation integrated system in the main control operation system and the training and checking system.
The simulation integrated system comprises a simulation operation mechanism, so that an operator can intuitively grasp the operation action of the equipment, the training effect is improved, further, the fault analysis and judgment can be conveniently and quickly performed by the technician, and the accuracy of assessment and evaluation is improved.
The main control operation system comprises a main control cabinet and an operation table, and the operation table is connected with the simulation operation mechanism through the main control cabinet. The main control cabinet integrates a processing unit module for platform operation, equipment monitoring diagnosis and training assessment, the integration degree is high, the main control cabinet is designed into an unsealed transparent open discharge cabinet, and the front panel is shielded by organic glass. The operation panel is equipped with operation instruction handle and the control button that the operation was accomplished to be equipped with monitoring diagnosis state display device and instruction interactive display device, let the technician grasp equipment running state and accomplish the whole operations to equipment operation maintenance restoration fast, improve technician's operating efficiency and reduce operating personnel's operation and go up the hand difficulty.
The remote diagnosis system comprises an action diagnosis module and a diagnosis communication module which are arranged in the simulation integrated system; the system comprises a diagnosis receiving module, a diagnosis signal analysis module, a diagnosis feedback module and a warning module which are arranged in a main control cabinet, wherein the action diagnosis module is arranged in a control mechanism of the simulation integrated system, the diagnosis communication module is arranged on the simulation integrated system, the action diagnosis module is in butt joint communication with the diagnosis receiving module through the diagnosis communication module, the diagnosis receiving module sends diagnosis information to the diagnosis signal analysis module, and the diagnosis signal analysis module sends analysis results to the diagnosis feedback module and the warning module after processing. The action diagnosis module arranged on the simulation integrated system equipment monitors and diagnoses each action point of the control mechanism in real time, and when equipment operation fails, the communication connection established by the diagnosis communication module and the diagnosis receiving module is combined, and the diagnosis signal analysis module and the diagnosis feedback module are used for rapidly analyzing and processing and feeding back the communication connection to technicians in time, so that the technicians can accurately remove the faults on the equipment and the system, and continuous and stable operation of the equipment is ensured.
The training and checking system comprises a grading training system and a comprehensive checking system, wherein the grading training system is provided with a simulation integrated system and an operation table which are connected into a central processing module of a main control cabinet. The hierarchical training system and the comprehensive assessment system are connected with the main control operation system and the simulation integration system in a monitoring joint control mode. The hierarchical training system monitors operation data of the main control operation system, and is used for performing hierarchical training on equipment control and operation by an operator in combination with the simulation integrated system. The comprehensive assessment system carries out comprehensive analysis by monitoring the acquired operation data of the main control operation system through the joint control simulation integrated system, and accurately carries out assessment and evaluation on the service proficiency of operators and technicians.
Preferably, the main control cabinet comprises a communication module, an I/O module, a serial port module, a signal input and output module, a storage module and a wireless receiving module which are connected with the central processing module; an operating state display module; a variable frequency control module; and the frequency conversion control module is connected with the simulation integrated system, and the power supply module is connected with the communication module, the signal input and output module, the storage module, the wireless receiving module and the running state display module for supplying power. The communication module is responsible for establishing information communication with the simulation integrated system and the training and checking system, the I/O module is used for being connected and combined with the equipment control assembly, the serial port module is used for establishing a wireless communication channel with the simulation integrated system and the main control operation system, the signal input and output module is used for receiving and analyzing feedback signals of all the systems and outputting feedback analysis results to corresponding systems, the storage module is used for storing processing data of the main control operation system, the training and checking system and the remote diagnosis system, the wireless receiving module is used for receiving wireless feedback signals, the running state display module is used for displaying running conditions of all modules in the feedback main control cabinet, the variable frequency control module is used for being connected with the simulation integrated system and controlling actions of equipment driving elements, and the power supply module comprises a power supply and a standby power supply and is used for guaranteeing normal and stable running of the main control cabinet.
Further, the console comprises an operation area; the system interaction operation panel is arranged at one side of the operation area, is connected with the simulation integrated system and the training and checking system and is used for adjusting action data; the system state display screen is arranged in front of the operation area and is used for displaying the running states of the simulation integrated system and the main control operation system and displaying the generated assessment model in cooperation with the training assessment system for assessment and evaluation by assessment staff.
Preferably, the system also comprises a wireless remote control system, wherein the wireless remote control system comprises a pairing module and an access control module which are arranged in a control space of the simulation integrated system; the wireless remote controller is provided with a code matching module, the code matching module can be matched to establish communication with the pairing module and is synchronously docked with the access control module, when the equipment operation control system fails, maintenance personnel can pair the code matching module with the corresponding pairing module of the failure equipment through the wireless remote controller on site to realize wireless remote control, and the equipment is quickly subjected to failure elimination.
Preferably, the dynamic pre-test system further comprises a dynamic pre-test system, wherein the dynamic pre-test system comprises a main control cabinet dynamic replacement interface, a dynamic replacement module, a dynamic detection module and a verification module, the connecting end of the main control cabinet dynamic replacement interface and the dynamic replacement module is in pluggable butt joint combination, the dynamic detection module and the verification module are connected with the main control cabinet dynamic replacement interface, the dynamic detection module is used for detecting the replacement matching accuracy of the dynamic replacement module, the verification module is used for verifying the operation function accuracy of the dynamic replacement module, and the dynamic pre-test system is in dynamic butt joint communication with the simulation integrated system and the main control operation system.
Preferably, the hierarchical training system comprises a login unit; a level setting unit; an operation instruction unit; an operation recording unit; and an operation feedback unit. The login unit checks the login information and then sends the login information to the grade setting unit, the grade setting unit controls the operation indicating unit to act, the operation recording unit obtains the action of the operation indicating unit and the actual operation action of the operation table and compares instruction data, and the operation feedback unit receives the instruction data comparison information processed by the operation recording unit.
Further, the grading training method of the large-scale equipment remote diagnosis and ECS training platform comprises the following steps,
s1: the training personnel inputs login information through the login unit,
s2: the grade setting unit sets the training grade and the training content according to the login information,
s3: the operation indication unit carries out training demonstration through a system state display screen of the main control cabinet linkage operation table and the simulation integrated system according to the content set in the step S2,
s4: the training personnel operates through the operation table according to the training demonstration of the S3, the operation recording unit records the operation process of the training personnel,
s5: the operation feedback unit receives the record data of the operation record unit, performs comparative analysis in the hierarchical training system in combination with the preset operation instruction, outputs the training operation analysis result, combines the result with the logged-in training personnel information for storage, feeds back the training operation result through the system state display screen,
S6: the login unit logs out training personnel information.
Preferably, the comprehensive assessment system comprises an assessment login unit; an assessment and distribution unit; an operation monitoring unit; programming an access unit; an operation analysis unit; the assessment scoring unit is arranged on the fault setting unit on the main control cabinet, and the fault triggering unit is connected with the simulation integrated system and the main control operating system. The assessment logging unit checks the assessment logging information and sends the assessment logging information to the assessment distribution unit, the assessment distribution unit and the fault setting unit send instructions to the fault triggering unit together, the operation monitoring unit obtains operation instruction information of the operation platform and a program adjusting instruction sent by the programming access unit connected to the main control operation system, the operation analysis unit receives the comprehensive operation instruction information processed by the operation monitoring unit and performs data analysis, and the assessment scoring unit compares scoring parameters in combination with operation data output by the operation analysis unit and then sends login information assessment data.
Further, the comprehensive assessment method for the remote diagnosis and ECS training platform of the large-scale equipment comprises the following steps:
s11: the assessment personnel inputs the assessment account information through the assessment login unit, the assessment login unit verifies the assessment personnel and the assessment account information, identifies the assessment grade of the assessment personnel,
S12: the assessment distribution unit obtains and generates an operation assessment model from the comprehensive assessment system according to the assessment account information, the fault setting unit sets a fault point to send out a fault instruction and the fault triggering unit is connected to act,
s13: the checking personnel find out the preset fault point and perform the fault elimination and repair operation by operating the operation table of the main control operation system and combining the simulation integrated system according to the checking model, and perform the correction operation on the fault point of the system by the programming access unit,
s14: the operation analysis unit records the examination operation process and operation time of the examination personnel, compares and analyzes the examination model repair result with the produced examination model faults, outputs examination analysis data to the examination scoring unit,
s15: the assessment scoring unit calculates and scores according to the correct processing number, the residual fault processing number, the time consumption of fault repair operation and the operation test running number of the preset fault points, gives assessment scoring grades, outputs assessment results, saves the assessment results into assessment account information,
s16: the assessment scoring unit outputs a preset assessment model restoration standard, and the assessment login unit logs out assessment personnel information.
Preferably, the assessment level of the assessment staff of the S11 comprises a primary assessment staff, a secondary assessment staff, a primary assessment staff and a high-grade assessment staff,
the number of fault points generated and set according to the assessment level is as follows:
the primary checking personnel set the number of fault points: 3-4;
the second-level assessment personnel set the number of fault points: 5-6;
the first-level assessment personnel set the number of fault points: 7-8;
the high-level assessment personnel set the number of fault points: at least 9 of the total number of the components is larger than or equal to 9,
the step S15 of giving the assessment score grade comprises the following steps: excellent, pass and fail.
Preferably, the setting of the fault point by the fault setting unit in S12 includes: lifting ascending/descending fault main command, cart left-going/right-going fault main command, trolley forward/backward fault main command, control button-closing fault main command, control button-breaking fault main command, rotary left/right-turning switch fault main command, lifting appliance pump switch fault main command, lifting appliance unlocking switch fault main command, middle lock telescopic selection fault main command, lifting appliance 20 ruler/40 ruler/45 ruler selection fault main command, wheel clamping device switch fault main command, locking pin advance/retreat pin indication fault main command, single/double box indication fault main command, cart anchoring indication fault main command and trolley anchoring indication fault main command.
Compared with the prior art, the invention has the beneficial effects that:
the invention adopts the simulation integrated system as the basis, the structure of the simulation integrated system is completely the same as that of the actual port operation equipment, an independent remote diagnosis system is configured in the simulation integrated system, and a set of training assessment system with completely the same function as that of the actual system is formed by combining the main control operation system and the training assessment system, so that an easy-to-use and practical service level lifting platform is provided for sustainable development of port production operation.
According to the invention, the hierarchical training system, the main control operation system and the simulation integration system in the training and checking system form a simulation training platform, and the simulation training platform is utilized to train the newly-entered staff before the post, so that the working condition in the field operation environment can be intuitively presented, the operator can conveniently perform the hand trial operation, and the safety is ensured. The grading training system can automatically form a matched training mode according to the grades of operators, the operators can know the operation skills to be mastered through demonstration before training, the training process feeds back the actual operation flow in real time through a system state display screen of an operation table, the remote diagnosis system is combined to visually display operation problems encountered in operation, the simulation training platform can record the operation process of the operators during training, and finally proper training guidance is given. The operation of the whole equipment can be more quickly familiar to operators in visual learning and manual operation modes, the operation steps are known and the safety operation education is carried out from shallow to deep, the safety of the operators using the equipment is improved, the equipment simulation operation and application are carried out on a simulation training platform, and the adjustment and simulation application of the equipment operation parameters can be carried out without safety risks.
According to the comprehensive assessment platform, the comprehensive assessment system, the main control operation system and the simulation integrated system in the training assessment system form the comprehensive assessment platform, the comprehensive assessment platform provides comprehensive assessment functions for all operators, objective and accurate technical assessment can be performed according to different assessment requirements, comprehensive technical assessment can be performed according to fault removal time, technical difficulty and fault processing efficiency, no matter whether electric and mechanical faults occur, the comprehensive assessment platform can be used for performing the most direct assessment, so that all operators can gradually improve the technical level of the operators in the comprehensive assessment platform, and all levels of operators can obtain improvement of the capability. Through the setting of the fault generated in advance or the signal shielding of the fault point, the sudden fault of the equipment is simulated, so that a technician can locate and repair the corresponding fault point or fault position through checking operation, and the capability of the technician is scored through the judgment description of the fault phenomenon, the speed and the accuracy of the fault point processing on site. And each technical evaluation and training result of the comprehensive assessment platform is used as a quantifiable reference standard for technical grade promotion of technicians.
The invention adds a wireless remote control system, extends to an automatic direction, bypasses the cab to operate in a remote control mode, controls equipment to operate in a remote control mode near port transportation equipment, is connected with a control wireless remote controller through wireless receiving transmission, controls the port transportation equipment to operate by using the wireless remote controller, simulates the operation of the on-site operation equipment by using the wireless remote controller when the equipment main control fails, eliminates equipment failure and maintains the normal operation of the port transportation equipment and the system.
The invention also provides a dynamic pre-test system, provides a dynamic test platform, can place a control element suspected of fault and repair on the training platform for dynamic test, tests the reliability of the conversion control of the software and hardware of the electric control system by replacing the components of the electric control system, tests the stability of the control system by replacing the control module, particularly tests the stability of each type of speed encoder of the operating handle, and tests the continuity of the whole communication by utilizing the communication module. The practical problem that maintenance personnel worry always is solved, and in the application of equipment, the unstable repair components and parts make equipment be in unsafe running state. The parameter setting and logic relation application of the complete machine electric control system is more intuitively known and tested, and the control of the repaired equipment is ensured not to be problematic in the use process in a safe mode environment.
Drawings
FIG. 1 is a schematic diagram of the steps of the hierarchical training method of the present invention.
FIG. 2 is a schematic diagram of the steps of the comprehensive examination method of the present invention.
Fig. 3 is a schematic diagram of a large-scale equipment remote diagnosis and ECS training platform of the present invention.
Fig. 4 is a schematic diagram of a master control cabinet according to the present invention.
FIG. 5 is a schematic diagram of a simulated integrated system according to the present invention.
FIG. 6 is a schematic diagram of an operation table according to the present invention.
Fig. 7 is a schematic diagram of a wireless remote controller according to the present invention.
Fig. 8 is a schematic diagram of a large equipment remote diagnosis and ECS training platform incorporating a wireless remote control system of the present invention.
Fig. 9 is a single line schematic diagram of a large equipment remote diagnosis and ECS training platform of the present invention.
FIG. 10 is a schematic diagram of a simulated animation interface of the present invention.
Detailed Description
The invention is further described below in connection with the following detailed description. Wherein the drawings are for illustrative purposes only and are shown in schematic, non-physical, and not intended to be limiting of the present patent; for the purpose of better illustrating embodiments of the invention, certain elements of the drawings may be omitted, enlarged or reduced and do not represent the size of the actual product; it will be appreciated by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.
The same or similar reference numbers in the drawings of embodiments of the invention correspond to the same or similar components; in the description of the present invention, it should be understood that, if there is an azimuth or positional relationship indicated by terms such as "upper", "lower", "left", "right", etc., based on the azimuth or positional relationship shown in the drawings, it is only for convenience of describing the present invention and simplifying the description, but it is not indicated or implied that the apparatus or element referred to must have a specific azimuth, be constructed and operated in a specific azimuth, and thus terms describing the positional relationship in the drawings are merely illustrative and should not be construed as limitations of the present patent, and specific meanings of the terms described above may be understood by those skilled in the art according to specific circumstances.
The invention is further described with reference to the following specific examples and the accompanying drawings:
FIGS. 1-10 are drawings for assisting in the explanation of a remote diagnosis and ECS training platform for large-scale equipment according to the present invention, which comprises a simulation integration system; a master control operating system connected with the simulation integrated system; and the remote diagnosis system is in butt joint with the simulation integrated system in the main control operation system and the training and checking system.
The simulation integrated system comprises a simulation operation mechanism, so that an operator can intuitively grasp the operation action of the equipment, the training effect is improved, further, the fault analysis and judgment can be conveniently and quickly performed by the technician, and the accuracy of assessment and evaluation is improved.
The main control operation system comprises a main control cabinet and an operation table, and the operation table is connected with the simulation operation mechanism through the main control cabinet. The main control cabinet integrates a processing unit module for platform operation, equipment monitoring diagnosis and training assessment, the integration degree is high, the main control cabinet is designed into an unsealed transparent open discharge cabinet, and the front panel is shielded by organic glass. The operation panel is equipped with operation instruction handle and the control button that the operation was accomplished to be equipped with monitoring diagnosis state display device and instruction interactive display device, let the technician grasp equipment running state and accomplish the whole operations to equipment operation maintenance restoration fast, improve technician's operating efficiency and reduce operating personnel's operation and go up the hand difficulty.
The remote diagnosis system comprises an action diagnosis module and a diagnosis communication module which are arranged in the simulation integrated system; the system comprises a diagnosis receiving module, a diagnosis signal analysis module, a diagnosis feedback module and a warning module which are arranged in a main control cabinet, wherein the action diagnosis module is arranged in a control mechanism of the simulation integrated system, the diagnosis communication module is arranged on the simulation integrated system, the action diagnosis module is in butt joint communication with the diagnosis receiving module through the diagnosis communication module, the diagnosis receiving module sends diagnosis information to the diagnosis signal analysis module, and the diagnosis signal analysis module sends analysis results to the diagnosis feedback module and the warning module after processing. The action diagnosis module arranged on the simulation integrated system equipment is used for carrying out real-time monitoring diagnosis on each action point of the equipment, when the equipment is in operation failure, the communication connection established by the diagnosis communication module and the diagnosis receiving module is combined, and the diagnosis signal analysis module and the diagnosis feedback module are used for rapidly analyzing and processing and feeding back the information to technicians in time, so that the technicians can accurately remove the failure occurring on the equipment and the system, and the continuous and stable operation of the equipment is ensured.
The training and checking system comprises a grading training system and a comprehensive checking system, wherein the grading training system is provided with a simulation integrated system and an operation table which are connected into a central processing module of a main control cabinet. The hierarchical training system and the comprehensive assessment system are connected with the main control operation system and the simulation integration system in a monitoring joint control mode. The hierarchical training system monitors operation data of the main control operation system, and is used for performing hierarchical training on equipment control and operation by an operator in combination with the simulation integrated system. The comprehensive assessment system carries out comprehensive analysis by monitoring the acquired operation data of the main control operation system through the joint control simulation integrated system, and accurately carries out assessment and evaluation on the service proficiency of operators and technicians.
Preferably, the main control cabinet comprises a communication module, an I/O module, a serial port module, a signal input and output module, a storage module and a wireless receiving module which are connected with the central processing module; an operating state display module; a variable frequency control module; and the power supply module is connected with the communication module, the signal input and output module, the storage module, the wireless receiving module and the running state display module for supplying power. The communication module is responsible for establishing information communication with the simulation integrated system and the training and checking system, the I/O module is used for being connected and combined with the equipment control assembly, the serial port module is used for establishing a wireless communication channel with the simulation integrated system and the main control operation system, the signal input and output module is used for receiving and analyzing feedback signals of all the systems and outputting feedback analysis results to corresponding systems, the storage module is used for storing processing data of the main control operation system, the training and checking system and the remote diagnosis system, the wireless receiving module is used for receiving wireless feedback signals, the running state display module is used for displaying running conditions of all modules in the feedback main control cabinet, the variable frequency control module is used for being connected with the simulation integrated system and controlling actions of equipment driving elements, and the power supply module comprises a power supply and a standby power supply and is used for guaranteeing normal and stable running of the main control cabinet.
Further, the console comprises an operation area; the system interaction operation panel is arranged at one side of the operation area, is connected with the simulation integrated system and the training and checking system and is used for adjusting action data; the system state display screen is arranged in front of the operation area and is used for displaying the running states of the simulation integrated system and the main control operation system and displaying the generated assessment model in cooperation with the training assessment system for assessment and evaluation by assessment staff.
Preferably, the system also comprises a wireless remote control system, wherein the wireless remote control system comprises a pairing module and an access control module which are arranged in a control space of the simulation integrated system; the wireless remote controller is provided with a code matching module, the code matching module can be matched to establish communication with the pairing module and is synchronously docked with the access control module, when the equipment operation control system fails, maintenance personnel can pair the code matching module with the corresponding pairing module of the failure equipment through the wireless remote controller on site to realize wireless remote control, and the equipment is quickly subjected to failure elimination.
Preferably, the dynamic pre-test system further comprises a dynamic pre-test system, wherein the dynamic pre-test system comprises a main control cabinet dynamic replacement interface, a dynamic replacement module, a dynamic detection module and a verification module, the connecting end of the main control cabinet dynamic replacement interface and the dynamic replacement module is in pluggable butt joint combination, the dynamic detection module and the verification module are connected with the main control cabinet dynamic replacement interface, the dynamic detection module is used for detecting the replacement matching accuracy of the dynamic replacement module, the verification module is used for verifying the operation function accuracy of the dynamic replacement module, and the dynamic pre-test system is in dynamic butt joint communication with the simulation integrated system and the main control operation system.
Preferably, the hierarchical training system comprises a login unit; a level setting unit; an operation instruction unit; an operation recording unit; and an operation feedback unit. The login unit checks the login information and then sends the login information to the grade setting unit, the grade setting unit controls the operation indicating unit to act, the operation recording unit obtains the action of the operation indicating unit and the actual operation action of the operation table and compares instruction data, and the operation feedback unit receives the instruction data comparison information processed by the operation recording unit.
Further, the grading training method of the large-scale equipment remote diagnosis and ECS training platform comprises the following steps,
s1: the training personnel inputs login information through the login unit,
s2: the grade setting unit sets the training grade and the training content according to the login information,
s3: the operation indication unit carries out training demonstration through a system state display screen of the main control cabinet linkage operation table and the simulation integrated system according to the content set in the step S2,
s4: the training personnel operates through the operation table according to the training demonstration of the S3, the operation recording unit records the operation process of the training personnel,
s5: the operation feedback unit receives the record data of the operation record unit, performs comparative analysis in the hierarchical training system in combination with the preset operation instruction, outputs the training operation analysis result, combines the result with the logged-in training personnel information for storage, feeds back the training operation result through the system state display screen,
S6: the login unit logs out training personnel information.
Preferably, the comprehensive assessment system comprises an assessment login unit; an assessment and distribution unit; an operation monitoring unit; programming an access unit; an operation analysis unit; the assessment scoring unit is arranged on the fault setting unit on the main control cabinet, and the fault triggering unit is connected with the simulation integrated system and the main control operating system. The assessment logging unit checks the assessment logging information and sends the assessment logging information to the assessment distribution unit, the assessment distribution unit and the fault setting unit send instructions to the fault triggering unit together, the operation monitoring unit obtains operation instruction information of the operation platform and a program adjusting instruction sent by the programming access unit connected to the main control operation system, the operation analysis unit receives the comprehensive operation instruction information processed by the operation monitoring unit and performs data analysis, and the assessment scoring unit compares scoring parameters in combination with operation data output by the operation analysis unit and then sends login information assessment data.
Further, the comprehensive assessment method for the remote diagnosis and ECS training platform of the large-scale equipment comprises the following steps:
s11: the assessment personnel inputs the assessment account information through the assessment login unit, the assessment login unit verifies the assessment personnel and the assessment account information, identifies the assessment grade of the assessment personnel,
S12: the assessment distribution unit obtains and generates an operation assessment model from the comprehensive assessment system according to the assessment account information, the fault setting unit sets a fault point to send out a fault instruction and the fault triggering unit is connected to act,
s13: the checking personnel find out the preset fault point and perform the fault elimination and repair operation by operating the operation table of the main control operation system and combining the simulation integrated system according to the checking model, and perform the correction operation on the fault point of the system by the programming access unit,
s14: the operation analysis unit records the examination operation process and operation time of the examination personnel, compares and analyzes the examination model repair result with the produced examination model faults, outputs examination analysis data to the examination scoring unit,
s15: the assessment scoring unit calculates and scores according to the correct number of the processing of the preset fault points, the residual number of the processing of the faults, the time consumption of the fault repairing operation and the operation test running times according to the assessment analysis data, gives assessment scoring grades, outputs assessment results, saves the assessment results into assessment account information,
s16: the assessment scoring unit outputs a preset assessment model restoration standard, and the assessment login unit logs out assessment personnel information.
Preferably, the assessment level of the assessment staff of the S11 comprises a primary assessment staff, a secondary assessment staff, a primary assessment staff and a high-grade assessment staff,
the number of fault points generated and set according to the assessment level is as follows:
the primary checking personnel set the number of fault points: 3-4;
the second-level assessment personnel set the number of fault points: 5-6;
the first-level assessment personnel set the number of fault points: 7-8;
the high-level assessment personnel set the number of fault points: at least 9 of the total number of the components is larger than or equal to 9,
the step S15 of giving the assessment score grade comprises the following steps: excellent, pass and fail.
Preferably, the setting of the fault point by the fault setting unit in S12 includes: lifting ascending/descending fault main command, cart left-going/right-going fault main command, trolley forward/backward fault main command, control button-closing fault main command, control button-breaking fault main command, rotary left/right-turning switch fault main command, lifting appliance pump switch fault main command, lifting appliance unlocking switch fault main command, middle lock telescopic selection fault main command, lifting appliance 20 ruler/40 ruler/45 ruler selection fault main command, wheel clamping device switch fault main command, locking pin advance/retreat pin indication fault main command, single/double box indication fault main command, cart anchoring indication fault main command and trolley anchoring indication fault main command.
Example 1:
when the large-scale equipment remote diagnosis and ECS training platform is used for hierarchical training:
the training personnel inputs own login information through the login unit, logs in the hierarchical training system, and simultaneously starts the simulation integrated system and the remote diagnosis system.
The grade setting unit of the grading training system sets training contents corresponding to the training grade according to the login information, the training grade of the training personnel and the training record, and enters the training.
The operation indicating unit of the hierarchical training system controls the simulation integration system to carry out training demonstration according to the training content through the system state display screens of the main control cabinet and the operation desk according to the training content set by the hierarchical setting unit, and the training personnel firstly observe and learn training.
After the observation, study and training are completed, training personnel perform operation control on the simulation integrated system by himself through the operation table according to the training demonstration content of the operation indication unit, and meanwhile, the operation recording unit records the operation of the training personnel in the actual operation process.
If the remote diagnosis system finds that misoperation leads to faults in the operation process of operators, a diagnosis signal is sent to a diagnosis receiving module through a diagnosis communication module, and a warning module controls to send out fault prompts.
The operation feedback unit of the grading training system receives training operation data recorded by the operation recording unit, performs comparison analysis in the grading training system in combination with a preset operation instruction, outputs training operation analysis results of logged-in training personnel, combines the results with logged-in training personnel information to be stored by the storage module of the main control cabinet, and finally feeds back training operation results through the system state display screen to enable training personnel to know training effects.
The training personnel exit the training personnel information through the login unit. After logging in again by new training personnel, corresponding grading training is carried out.
Example 2:
when the large-scale equipment remote diagnosis and ECS training platform is used for comprehensive examination:
the assessment personnel inputs own assessment account information through the assessment login unit, the assessment login unit verifies the assessment personnel and the assessment account information, the assessment grade of the assessment personnel is identified, the comprehensive assessment system login is completed, and meanwhile, the simulation integrated system and the remote diagnosis system are started.
The assessment distribution unit of the comprehensive assessment system acquires and generates an operation assessment model from the comprehensive assessment system according to the assessment grade of the assessment account information, and the fault setting unit sets a fault point to send a fault instruction and is connected with the fault triggering unit for action.
Identifying the assessment grade of an assessment person as a primary assessment person in the comprehensive assessment system, generating an operation assessment model and setting 3-4 set fault points by a fault setting unit;
identifying the assessment level of the assessment personnel as a secondary assessment personnel in the comprehensive assessment system, generating an operation assessment model and setting 5-6 set fault points by a fault setting unit;
identifying the assessment level of the assessment personnel as a set of assessment personnel in the comprehensive assessment system, generating an operation assessment model and setting 7-8 set fault points by a fault setting unit;
and identifying the assessment grade of the assessment personnel as an advanced assessment personnel in the comprehensive assessment system, generating an operation assessment model and setting at least 9 set fault points by a fault setting unit.
The fault point set by the fault setting unit can select any item from lifting ascending/descending fault main command, left/right running fault main command of a cart, forward/backward fault main command of a cart, control closing button fault main command, control breaking button fault main command, turning left/right turning switch fault main command, lifting appliance pump switch fault main command, lifting appliance opening and closing switch fault main command, middle lock telescopic selection fault main command, lifting appliance 20 ruler/40 ruler/45 ruler selection fault main command, wheel clamping device switch fault main command, locking pin advance/withdraw pin indication fault main command, single/double box indication fault main command, cart anchoring indication fault main command and combination thereof.
And the assessment personnel find out a preset fault point and conduct fault elimination and repair operation by operating an operation table of a main control operation system and combining with observation of the operation of the simulation integrated system according to an assessment model, and when a logic layer breaks down, the assessment personnel conduct correction operation on the fault point of the system through a programming access unit.
The operation analysis unit of the comprehensive assessment system records the assessment operation process and operation time of assessment personnel, compares and analyzes the assessment model repair result with the produced assessment model faults, and outputs assessment analysis data to the assessment scoring unit, wherein the comparison analysis comprises fault operation data such as correct processing and error processing quantity of preset fault points, processing residual quantity of the fault points, time consumption of fault repair operation, operation test running times and the like.
The assessment scoring unit of the comprehensive assessment system calculates and scores according to the assessment analysis data, the correct processing number of the preset fault points, the residual processing number of the fault points, the time consumption of fault repair operation and the operation test running times, gives assessment scoring grades (the assessment scoring grades can refer to the following assessment scoring grade reference table, the assessment scoring grade reference table is a scoring grade example), outputs an assessment result, and stores the assessment result into the assessment account information.
Assessment score grade reference table
And the assessment scoring unit of the comprehensive assessment system outputs a preset assessment model restoration standard through a system state display screen, and finally an assessment person logs out the information of the assessment person through the assessment login unit and exits the comprehensive assessment system.
Example 3:
when the wireless remote control system is used for accessing the simulation integrated system, the code matching module of the wireless remote controller is matched with the code matching module, so that after the code matching module is matched with the built-in code matching module, the wireless remote controller and the access control module establish wireless communication, the wireless remote controller is in butt joint communication with the simulation integrated system, the wireless remote controller is accessed into the main control operation system, an operator realizes the control of the simulation integrated system by operating the wireless remote controller, the wireless remote controller controls the simulation integrated system to carry out transportation operation, and remote control auxiliary operation is realized.
Example 4:
when the dynamic pre-test system is used for pre-debugging and operation verification operation of components and hardware of the replacement electronic control system, after a connection interface of the replacement software and hardware is connected with a dynamic replacement interface of the main control cabinet, the dynamic detection module detects the replacement software and hardware, the dynamic replacement module controls the corresponding replaced software and hardware to be disconnected and connected with the system, the replacement software and hardware is directly connected with the large-scale equipment remote diagnosis and ECS training platform for dynamic pre-test verification, a crew can quickly and intuitively master the availability and stability of the replacement software and hardware by observing the operation condition of the large-scale equipment remote diagnosis and ECS training platform, and after the dynamic pre-test verification is passed, the crew can connect the replacement software and hardware into the main system for the main system to maintain normal operation.
The control element suspected of faults and repaired can be placed on a training platform to carry out dynamic test by utilizing the dynamic pre-test system, the reliability of the transformation control of the software and hardware of the electric control system is tested by replacing components of the electric control system, the stability of the control system is tested by replacing a control module, particularly the stability of each type of speed encoder of an operation handle is tested, and the continuity of the whole communication is tested by utilizing a communication module. The practical problem that maintenance personnel worry always is solved, and in the application of equipment, the unstable repair components and parts make equipment be in unsafe running state. The parameter setting and logic relation application of the complete machine electric control system is more intuitively known and tested, and the control of the repaired equipment is ensured not to be problematic in the use process in a safe mode environment.
It is to be understood that the above examples of the present invention are provided by way of illustration only and not by way of limitation of the embodiments of the present invention. Other variations or modifications of the above teachings will be apparent to those of ordinary skill in the art. It is not necessary here nor is it exhaustive of all embodiments. Any modification, equivalent replacement, improvement, etc. which come within the spirit and principles of the invention are desired to be protected by the following claims.

Claims (10)

1. The remote diagnosis and ECS training platform for the large-scale equipment is characterized by comprising a simulation integrated system; a master control operating system connected with the simulation integrated system; a remote diagnosis system and a training and checking system which are in butt joint with the simulation integrated system in the main control operation system,
the simulation integrated system comprises a simulation operation mechanism, the main control operation system comprises a main control cabinet and an operation table, the operation table is connected with the simulation operation mechanism through the main control cabinet,
the remote diagnosis system comprises an action diagnosis module and a diagnosis communication module which are arranged in the simulation integrated system; the action diagnosis module is arranged in a control mechanism of the simulation integrated system, the diagnosis communication module is arranged on the simulation integrated system, the action diagnosis module is in butt joint communication with the diagnosis receiving module through the diagnosis communication module, the diagnosis receiving module sends diagnosis information to the diagnosis signal analysis module, the diagnosis signal analysis module processes the analysis result and sends the analysis result to the diagnosis feedback module and the warning module,
The training and checking system comprises a grading training system and a comprehensive checking system, wherein the grading training system and the comprehensive checking system are connected with a simulation integrated system and an operation table in a central processing module of a main control cabinet, and the grading training system and the comprehensive checking system are connected with the main control operation system and the simulation integrated system for monitoring and combined control.
2. The large-scale equipment remote diagnosis and ECS training platform according to claim 1, wherein the main control cabinet includes a communication module, an I/O module, a serial port module, a signal input and output module, a storage module, and a wireless receiving module, which are connected with the central processing module; an operating state display module; a variable frequency control module; the frequency conversion control module is connected with the simulation integrated system, the power supply module is connected with the communication module, the signal input and output module, the storage module, the wireless receiving module and the running state display module for supplying power, and the operation platform comprises an operation area; a system interactive operation panel arranged at one side of the operation area; and a system status display screen disposed in front of the operation area.
3. The large scale equipment remote diagnosis and ECS training platform of claim 1, further comprising a wireless remote control system including a pairing module and an access control module disposed within a control space of the simulation integration system; the wireless remote controller is provided with a code matching module, and the code matching module can be used for matching the code, establishing communication with the matching module and synchronously butting with the access control module.
4. The remote diagnosis and ECS training platform of the large-scale equipment according to claim 1, further comprising a dynamic pre-test system, wherein the dynamic pre-test system comprises a main control cabinet dynamic replacement interface, a dynamic replacement module, a dynamic detection module and a verification module, the connecting ends of the main control cabinet dynamic replacement interface and the dynamic replacement module are in pluggable butt joint combination, the dynamic detection module and the verification module are connected with the main control cabinet dynamic replacement interface, the dynamic detection module is used for detecting the replacement matching accuracy of the dynamic replacement module, the verification module is used for verifying the operation function accuracy of the dynamic replacement module, and the dynamic pre-test system is in dynamic butt joint communication with the simulation integrated system and the main control operation system.
5. The large equipment remote diagnosis and ECS training platform of claim 1, characterized in that the hierarchical training system includes a login unit; a level setting unit; an operation instruction unit; an operation recording unit; the operation feedback unit is used for transmitting the login information to the grade setting unit after checking the login information, the grade setting unit is used for controlling the operation indicating unit to act, the operation recording unit is used for acquiring the action of the operation indicating unit and the actual operation action of the operation table and comparing instruction data, and the operation feedback unit is used for receiving the instruction data comparison information processed by the operation recording unit.
6. The method for hierarchical training of a large facility remote diagnosis and ECS training platform of claim 5, comprising the steps of,
s1: the training personnel inputs login information through the login unit,
s2: the grade setting unit sets the training grade and the training content according to the login information,
s3: the operation indication unit carries out training demonstration through a system state display screen of the main control cabinet linkage operation table and the simulation integrated system according to the content set in the step S2,
s4: the training personnel operates through the operation table according to the training demonstration of the S3, the operation recording unit records the operation process of the training personnel,
s5: the operation feedback unit receives the record data of the operation record unit, performs comparative analysis in the hierarchical training system in combination with the preset operation instruction, outputs the training operation analysis result, combines the result with the logged-in training personnel information for storage, feeds back the training operation result through the system state display screen,
s6: the login unit logs out training personnel information.
7. The large scale equipment remote diagnosis and ECS training platform of claim 1, wherein the comprehensive assessment system includes an assessment log-in unit; an assessment and distribution unit; an operation monitoring unit; programming an access unit; an operation analysis unit; the assessment scoring unit is arranged on the main control cabinet, the fault triggering unit is connected with the simulation integrated system and the main control operation system, the assessment logging unit checks the assessment logging information and sends the assessment logging information to the assessment distribution unit, the assessment distribution unit and the fault setting unit send instructions to the fault triggering unit together, the operation monitoring unit acquires the operation instruction information of the operation table and the program adjusting instruction sent by the programming access unit connected to the main control operation system, the operation analysis unit receives the comprehensive operation instruction information processed by the operation monitoring unit and performs data analysis, and the assessment scoring unit compares the scoring parameters by combining the operation data output by the operation analysis unit and then sends the logging information assessment data.
8. The comprehensive assessment method for a large-scale equipment remote diagnosis and ECS training platform of claim 7, comprising the steps of:
s11: the assessment personnel inputs the assessment account information through the assessment login unit, the assessment login unit verifies the assessment personnel and the assessment account information, identifies the assessment grade of the assessment personnel,
s12: the assessment distribution unit obtains and generates an operation assessment model from the comprehensive assessment system according to the assessment account information, the fault setting unit sets a fault point to send out a fault instruction and the fault triggering unit is connected to act,
s13: the checking personnel find out the preset fault point and perform the fault elimination and repair operation by operating the operation table of the main control operation system and combining the simulation integrated system according to the checking model, and perform the correction operation on the fault point of the system by the programming access unit,
s14: the operation analysis unit records the examination operation process and operation time of the examination personnel, compares and analyzes the examination model repair result with the produced examination model faults, outputs examination analysis data to the examination scoring unit,
s15: the assessment scoring unit calculates and scores according to the correct processing number, the residual fault processing number, the time consumption of fault repair operation and the operation test running number of the preset fault points, gives assessment scoring grades, outputs assessment results, saves the assessment results into assessment account information,
S16: the assessment scoring unit outputs a preset assessment model restoration standard, and the assessment login unit logs out assessment personnel information.
9. The comprehensive assessment method for the large-scale equipment remote diagnosis and ECS training platform according to claim 8, wherein the assessment level of the assessment staff of S11 comprises a primary assessment staff, a secondary assessment staff, a primary assessment staff and a high-grade assessment staff,
the number of fault points generated and set according to the assessment level is as follows: the primary checking personnel set the number of fault points: 3-4; the second-level assessment personnel set the number of fault points: 5-6; the first-level assessment personnel set the number of fault points: 7-8; the high-level assessment personnel set the number of fault points: at least 9 of the total number of the components is larger than or equal to 9,
the step S15 of giving the assessment score grade comprises the following steps: excellent, pass and fail.
10. The method for remote diagnosis of large-scale equipment and comprehensive assessment of ECS training platform according to one of claims 8 or 9, wherein the fault setting unit sets a fault point in S12 includes: lifting ascending/descending fault main command, cart left-going/right-going fault main command, trolley forward/backward fault main command, control button-closing fault main command, control button-breaking fault main command, rotary left/right-turning switch fault main command, lifting appliance pump switch fault main command, lifting appliance unlocking switch fault main command, middle lock telescopic selection fault main command, lifting appliance 20 ruler/40 ruler/45 ruler selection fault main command, wheel clamping device switch fault main command, locking pin advance/retreat pin indication fault main command, single/double box indication fault main command, cart anchoring indication fault main command and trolley anchoring indication fault main command.
CN202311021415.2A 2023-08-14 2023-08-14 Large-scale equipment remote diagnosis and ECS training platform Pending CN117198102A (en)

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