CN206671500U - Integrated motor intellectuality big data on-Line Monitor Device - Google Patents

Abstract

The utility model relates to an integrated motor intelligent big data online monitoring device, which belongs to the field of motor intelligent online monitoring. It includes a current acquisition module, a voltage acquisition module, a temperature acquisition module, a rotational speed acquisition module, an environmental parameter acquisition module, a data analysis and processing module, a calendar module, a storage module, a communication module and a power supply module. The device is installed when the motor leaves the factory, and is integrated with the motor, collects various operating parameters of the motor and sends them to the data analysis and processing module for analysis and processing, and establishes a large database of real-time operating parameters of the motor; at the same time, it performs health status diagnosis and operating parameters of the motor Judging the change trend, and sending early warning or alarm signals to the portable device and the control center in time through the communication module. This system realizes intelligent long-term, continuous and real-time collection of motor operating parameters. The integrated installation method saves space and reduces costs. It can be widely used in intelligent online monitoring of various motors.

Description

Integrated motor intelligent big data online monitoring device

technical field

The utility model relates to a motor monitoring technology, in particular to an integrated intelligent motor operation big data online monitoring device. The invention belongs to the field of intelligent online monitoring of motors.

Background technique

At present, motors are widely used in various fields of national economy, but the degree of intelligence of motors is very low. With the rapid development of intelligent manufacturing, smart factories have higher and higher requirements for motor intelligence, including intelligent fault diagnosis, intelligent status warning, intelligent operation control, intelligent operation management, intelligent maintenance and intelligent energy efficiency control during the operation of the motor. There is an urgent need for an intelligent online monitoring device that can be integrated with the motor to realize long-term, continuous and real-time comprehensive operation of big data monitoring during the operation of the motor.

At present, the operation monitoring of motors is mainly aimed at large motors or special motors, and all of them adopt the mode of multiple split devices and temporary installation. For example, the Chinese patent "Distributed Intelligent Motor Monitoring System" (application number: 200410034967.8) proposes a "system capable of realizing single or multiple synchronous Distributed intelligent motor monitoring system with high precision, safety and reliability requirements". Realized the distributed real-time collection of motor running data, centralized real-time identification and fault diagnosis of motor running status. However, multiple discrete monitoring devices and instruments are used to collect parameters after post-installation. It is inconvenient to install and disassemble. Some sensors even need to disassemble the motor for installation and disassembly. The cost is high, the structure is complex, and the space is large. It is only suitable for large or important. The motor is temporarily used, not universal, and it is difficult to accumulate large data on motor operation; in addition, the purpose of this system monitoring is for motor testing, or for real-time identification of operating status and fault diagnosis on the server, and on-site monitoring of the motor is not possible. The early warning and various data of the motor can be used directly on site, let alone provide data for the intelligent operation control of the motor; moreover, the motor manufacturer cannot obtain the data and analyze and utilize it.

Another example is the Chinese patent "A High-Voltage Motor Intelligent Monitoring System and Monitoring Method" (Application No.: 201410721965.X) which provides a high-voltage motor intelligent monitoring system and monitoring method, which enables motor manufacturers to remotely collect real-time data of motors, and Carry out big data analysis on these data to find out the faults and potential faults of the motor, and download the methods to solve these faults to the site, and remotely assist users to eliminate motor faults and potential faults. However, this invention only proposes a system framework for after-sales service for motor manufacturing enterprises. The data monitoring part uses split equipment, which is costly and inconvenient to install and maintain; the purpose of the invention is only to remotely assist users to eliminate faults. It is still impossible to directly use the original data, and it is far from meeting the technical requirements of intelligent manufacturing for intelligent motors.

In addition, motor faults are caused by many factors, including motor design defects, operating environment, working mode, operating conditions, etc., and the occurrence of motor faults is a gradual process, and there will be abnormal operation before the fault occurs If the abnormal operation status or failure precursor of the motor can be found in advance, and the repair and maintenance can be carried out in advance, the failure can be effectively prevented, the production plan can be adjusted in advance, and the normal production can be effectively avoided; at the same time, the motor’s Intelligent control also requires the support of real-time operating parameters of the motor. This can only be realized by relying on the long-term, continuous and real-time collection and accumulation of comprehensive operation big data during the operation of the motor.

Contents of the invention

In order to overcome the deficiencies of the prior art, the utility model proposes an integrated motor intelligent big data online monitoring device. The motor operation parameter acquisition device and the corresponding sensors are pre-integrated and installed on the motor, and integrated with the motor to realize long-term, continuous and real-time comprehensive operation big data collection and accumulation during the operation of the motor, and carry out on-site motor monitoring. Working status identification, judgment and early warning. A variety of communication interfaces are provided to directly provide basic big data for intelligent fault diagnosis, intelligent status warning, intelligent control, intelligent operation management, and intelligent repair and maintenance of motor operation. The utility model has the advantages of simple structure, no post-installation, convenient use, low cost and the like.

The technical scheme that the utility model solves its technical problem adopts is:

The integrated motor intelligent big data online monitoring device includes a current acquisition module (1), a voltage acquisition module (2), a temperature acquisition module (3), a rotational speed acquisition module (4), an environmental parameter acquisition module (5), A data analysis and processing module (6), a calendar module (7), a storage module (8), a communication module (9), a power supply module (10), and a casing (11).

The current acquisition module (1) is installed at the motor inlet line (13) in the motor junction box (12), collects the real-time running current of the motor, and sends it to the data analysis and processing module (6).

The voltage acquisition module (2) is installed at the motor inlet line (13) in the motor junction box (12), collects the real-time operating voltage of the motor, and sends it to the data analysis and processing module (6).

The temperature acquisition module (3) is installed on the motor internal components (14), collects the real-time operating temperature of the motor internal components (14), and sends them to the data analysis and processing module (6).

The speed acquisition module (4) is installed on the side of the internal rotating part (15) of the motor, collects the real-time running speed of the motor, and sends it to the data analysis and processing module (6).

The environmental parameter acquisition module (5) is installed on the outer surface of the casing (11), collects real-time environmental parameters when the motor is running, and sends them to the data analysis and processing module (6).

Through the above installation method, when the motor is manufactured, the acquisition module of various operating parameters is pre-built into the motor body, and integrated with the motor. After the motor is put into operation, there is no need to disassemble and install it; , When designing the motor, it is also necessary to reserve a suitable installation space and location for the acquisition modules of various operating parameters, which solves the problems of troublesome disassembly and difficult installation during later installation.

The data analysis and processing module (6) is located in the casing (11), and after real-time processing of the collected continuous current, voltage, temperature, speed, and environmental parameter data, combined with the current time information obtained from the calendar module (7) , store in the storage module (8), and exchange data with the portable device (16) or the control center (17) through the communication module (9); the portable device (16) can be a general-purpose smart phone, and a dedicated APP can be installed , it can also be a special handheld device, etc.

The power supply module (10) is located in the casing (11), and its input wire is connected from the motor inlet wire (13) to provide power for the device.

The casing (11) is a closed metal shielding casing, which is fixed on the motor casing (19) through a fixing mechanism (18), or integrated with the motor casing (19), or integrated with the motor junction box (12).

The formation of motor operation big data requires the collection of motor operation data of different models, different operating conditions, and different operating environments. Traditional monitoring equipment and motors are separated, which also leads to high cost, large volume, cumbersome installation process, Applicability is small and many other defects. When the motor is designed and manufactured, a space is reserved for the monitoring device, and internal wiring is used. The device and the motor are integrated during manufacture, so that each motor has its own intelligent monitoring platform, which is extremely convenient to realize the online operation of the big data of the motor. collection and direct use.

The data analysis and processing module (6) calculates and counts the derived operating parameters based on the directly measured real-time operating parameters of the motor, including the instantaneous value and effective value of the power, the spectrum of the harmonic, the power within the set time period, and the set time The times and trends or characteristics of voltage, current, and temperature abnormalities within a segment, the start-stop time, times, and load rate changes of the motor within a set period of time are stored.

The operating parameters of the motor contain important information reflecting the operating state of the motor, but in general it is difficult to directly observe the characteristics of the signal, so an appropriate method must be used to process the original signal to extract sensitive features that can reflect the fault symptoms quantity.

The calculated derived operating parameters include power quality information such as frequency, harmonics, and voltage, electric energy information such as active power, reactive power, apparent power, and power consumption; and the maximum, minimum, and average values of each operating parameter , effective value and other feature information. The derived operating parameters obtained from statistics include the time, frequency and scale of voltage flicker, swell, sag, reclosing, load fluctuation, etc.; and work management information such as start-stop time, frequency, load rate change and time interval. Compare and analyze the original parameters and derived parameters with standard indicators and historical data, and send an early warning signal to external equipment once the early warning requirements are met.

The data analysis and processing module (6) performs motor health status diagnosis and operating parameter change trend according to the directly measured real-time operating parameters and calculated and statistically derived operating parameters, combined with the historical data in the storage module (8) Judging and calculating the corresponding characteristic parameters at the same time, identifying the characteristics of fault precursors and abnormal operating conditions, and sending relevant data and early warning information to the portable device (16) or the control center (17).

According to a large number of accident statistics and analysis results, motor faults are usually caused by insufficient attention to early fault symptoms. Due to the failure to detect and deal with them in time, they develop into malignant faults. Whether the motor can operate safely and reliably requires the analysis, judgment and early warning of the cause of the motor, the characteristics of the fault symptoms, and the development and change trend of the operating parameters, etc., all of which rely on the accumulation of a large amount of motor operating data and targeted characteristic analysis. .

Identify the state of the motor through various characteristic parameters and other derived information of the motor operation, determine the location and severity of the fault, point out the trend and consequences of the fault development, and propose the operation and maintenance countermeasures to control the continued development of the fault and eliminate the fault. So as to realize the improvement from traditional preventive maintenance to preventive condition maintenance. The abnormal situation of the motor can be detected and warned in time, so that the staff can grasp the signs of failure in time, deal with the abnormal operation of the motor as soon as possible, and avoid the expansion of motor faults, thereby effectively reducing the failure rate and damage rate of the motor system. The cost of equipment is saved, and the serious loss caused by unexpected equipment failure is avoided.

Among the motor faults, more than 65% are related to electrical and mechanical faults. There is a certain connection between mechanical faults and electrical faults. Many mechanical faults are manifested through the electrical characteristics of the motor, such as the current, voltage, and insulation of the stator winding. resistance, etc. The electrical parameters of the motor are important data for the analysis of the motor's operating state, and are also an important manifestation of the effects of various motor control strategies. Therefore, the information measured by the device can be used for diagnosis and early warning of most motor faults.

The temperature collection module (3) includes a plurality of temperature probes, and simultaneously collects the temperature of multiple parts of the internal components (14) of the motor.

Accompanied by the occurrence of motor failure, the phenomenon of motor overheating generally occurs, and overheating is very detrimental to the insulation of the motor. Each insulating material can only withstand a certain temperature. If the temperature exceeds its own allowable temperature, it will accelerate the aging of the insulation, shorten the service life of the motor, and may cause various accidents due to insulation damage. Therefore, the inspection, detection and protection of motor overheating faults are very important for reducing the accident rate and accident losses and improving the economic benefits of enterprises.

Temperature acquisition is an important component of motor operation big data. Based on the heat-generating parts easily caused by the abnormal operation of the motor, the integrated monitoring equipment directly installs the temperature probes on the stator yoke, stator winding, stator end winding and other parts when the motor leaves the factory to monitor the temperature of each part of the motor in real time, which is helpful Fault warning and life prediction. Moreover, some special parts, such as stator windings, cannot be installed with temperature probes after the motor is put into operation.

The environmental parameter acquisition module (5) measures the environmental parameters of the motor working area, including ambient temperature, humidity, dust concentration and air pressure, etc., and sends them to the data analysis and processing module (6) for auxiliary analysis and storage. The environment has a great influence on the health and life of the motor. For example, if the insulation of the motor winding is damaged, and the conductor of the winding, the iron core, and the casing collide, the winding is grounded. At this time, the current of the phase winding will be too large. Local heating will burn the windings in severe cases. The occurrence of winding grounding is mostly caused by the motor being damp, and some are caused by metal objects or harmful powder entering the inside of the motor winding when the environment is harsh. Therefore, real-time monitoring of environmental parameters and timely reminders to operators to improve the operating environment are conducive to keeping the motor in the best operating state. At the same time, operating environmental parameters are also helpful for judging the characteristics of motor failure precursors and assisting in evaluating the health status of the motor. , Predict the service life of the motor, etc.

The communication module (9) includes a short-distance wireless communication module (901), a long-distance wireless communication module (902) and a wired communication module (903). The short-distance wireless communication module (901) is used for communicating with the portable device (16). The distance wireless communication module (902) is used for communication with the control center (17), and the wired communication module (903) is used for networking between motors or exchanging data with the motor control device.

The communication module (9) communicates with the outside world through wired or wireless methods, and the interface can be in various ways, such as Bluetooth, Zigbee, wifi, Ethernet port, serial port (RS232, RS485), USB, carrier and bus interface (MBUS, CAN) part or all of . It can communicate with the motor control device through the wired communication interface, and send the collected operating parameters to the motor control device to realize control optimization. The communication module (9) can also be used to realize the networked monitoring of the motor operation, and the information can be sent to the portable device (16) and the control center (17) at any time, which facilitates production, operation and big data management.

The device also includes a storage battery (20), connected to the power module (10). In order for the staff to know the running status of the motor at any time, in some occasions, no matter whether the motor is running or not, the monitoring equipment needs to collect data at all times and maintain communication with other devices at all times. The accumulator (20) is charged when the motor is running, and the device is kept working when the motor is stopped, and the staff can know the state of the motor at any time.

All exposed parts of the device are provided with dust-proof, dirt-proof and water-proof measures. Some motors work in harsh environments. Necessary preventive measures ensure the reliability of the device in extreme environments, prolong the service life of the device, and avoid the blockage of the interface, which is convenient for better connection with external devices. When the exposed communication interface is not in use, it can be sealed with rubber, and the rubber filling at the entrance of the line can be taken.

Compared with the prior art, the utility model has the following advantages:

1) The intelligent online monitoring device of the motor is integrated with the motor structure, which realizes the long-term, continuous and real-time collection and accumulation of comprehensive operation big data during the operation of the motor, greatly reducing the cost of monitoring with distributed instruments, and The measured real-time operating parameters of the motor can be directly used, and has the advantages of simple structure, convenient transportation, no post-installation, convenient use, and low cost.

2) By adopting the method of integrating with the motor, without adding any equipment, the motor working status can be identified, judged and warned on the spot, so that the user can easily grasp the working status of the motor, and understand the abnormal running status of the motor and Timely processing of fault precursors effectively avoids damage to the motor and major economic losses caused by unexpected production interruptions, and realizes intelligent fault diagnosis and intelligent state early warning of the motor.

3) When the motor needs to perform intelligent operation control or energy efficiency optimization and control, the corresponding control system does not need to be additionally equipped with a data acquisition device, and uses the communication interface provided by the motor intelligent online monitoring device to directly obtain the real-time operating parameters of the motor, simplifying the The structure of the control system is improved, and the cost is further reduced for the enterprise.

4) Using the big data collected by the intelligent online monitoring device of the motor, the production enterprise can directly carry out the intelligent operation management, intelligent repair and maintenance of the production equipment; and the motor manufacturer can also use the big data to effectively improve the after-sales service life of the product. Efficiency and quality, and through the statistical analysis of motor operation big data, find the design and manufacturing defects of the motor, optimize the design and improvement of the product, etc.

Description of drawings

Figure 1: Block diagram of the device.

Figure 2: Schematic diagram of the installation of the external structure of the device.

In the figure: 1-current acquisition module, 2-voltage acquisition module, 3-temperature acquisition module, 4-speed acquisition module, 5-ambient temperature and humidity acquisition module, 6-data analysis and processing module, 7-calendar module, 8-storage Module, 9-communication module, 901-short-range wireless communication module, 902-long-distance wireless communication module, 903-wired communication module, 10-power supply module, 11-housing, 12-motor junction box, 13-motor incoming line , 14-internal components of the motor, 15-internal rotating parts of the motor, 16-portable equipment, 17-control center, 18-fixing mechanism, 19-motor shell, 20-battery.

detailed description

Below in conjunction with accompanying drawing, the utility model is described in further detail:

Figure 1 is a block diagram of the device. In the figure, the data analysis and processing module (6), the calendar module (7), the storage module (8), the communication module (9), the power supply module (10) and the storage battery (20) are integrated and placed in the housing (11) as a whole. The power supply module (10) takes power from the motor inlet (13) to provide power for other modules. The battery (20) is connected to the power supply module (10) for charging under normal conditions, and provides backup for the device when the motor is powered off and stops running. power supply.

The current collection module (1) and the voltage collection module (2) collect the three-phase voltage and current from the motor incoming line (13), and convert the current and voltage into a range that can be measured by the device through the current transformer and the voltage transformer respectively.

The contacts of the temperature acquisition module (3) are respectively installed on the internal components (14) of the motor such as the stator yoke, the stator winding, and the stator end winding. The speed acquisition module (4) is installed at the internal rotating part (15) of the motor. The environmental parameters The contacts of the acquisition module (5) are installed outside the housing (11).

The current acquisition module (1), voltage acquisition module (2), temperature acquisition module (3), speed acquisition module (4) and environmental parameter acquisition module (5) are directly welded to the installation place when the motor leaves the factory, and are integrated with the motor change.

Current acquisition module (1), voltage acquisition module (2), temperature acquisition module (3), speed acquisition module (4), environmental parameter acquisition module (5), calendar module (7), storage module (8) and communication module (9) are respectively connected to the data analysis and processing module (6), and the data analysis and processing module (6) supplies power to the modules connected to it. The wires of the current acquisition module (1), voltage acquisition module (2), temperature acquisition module (3) and speed acquisition module (4) all pass through the motor junction box (12), and the collected real-time data are transmitted to data analysis and processing The module (6) performs data analysis and stores the data in the storage module (8).

The communication module (9) integrates a short-distance wireless communication module (901), a long-distance wireless communication module (902) and a wired communication module (903), and the short-distance wireless communication module (901) is used to communicate with the portable device (16). In order for the operation and maintenance personnel to understand the running status of the motor; the long-distance wireless communication module (902) is used to communicate with the control center (17) to manage the big data of motor operation; the wired communication module (903) is used for equipment networking or transmission to control equipment data.

The data analysis and processing module (6) diagnoses the health state of the motor and judges the change trend of the operating parameters, and calculates the corresponding characteristic parameters at the same time, identifies the characteristics of the fault precursor and the abnormal operating state, and sends the report to the portable device (16) or the control center (17) Send relevant data and early warning information.

In order to further illustrate the application of the device, Figure 2 is a schematic diagram of the installation of the external structure of the device. In the figure, the current acquisition module (1) and the voltage acquisition module (2) collect the three-phase voltage and current from the motor incoming line (13) in the motor junction box (12), and respectively pass the current transformer and the voltage transformer to the current and voltage Converted to the measurable range of the device. The power supply module (10) takes 220V or 380V AC from the motor inlet (13), and after rectification, filtering, and voltage stabilization, converts it into 5V DC to provide power for other modules. The environmental parameter acquisition module (5) is installed on the outside of the casing (11) to collect the environmental parameters of the motor. The casing (11) is welded on the outer surface of the motor or fixed on the motor casing (19) by a fixing mechanism (18) when the motor leaves the factory.

The above descriptions are only preferred implementation examples of the present utility model, and are not intended to limit the present utility model. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present utility model shall be included in this utility model. within the scope of protection of utility models.

Claims (8)

1. integrated motor intellectuality big data on-Line Monitor Device, it is characterised in that：Device includes current acquisition module（1）、 Voltage acquisition module（2）, temperature collect module（3）, rotating speed acquisition module（4）, ambient parameter acquisition module（5）, data analysis Processing module（6）, calendaring module（7）, memory module（8）, communication module（9）, power module（10）, housing（11）；

Current acquisition module（1）Installed in connection box for motor（12）Interior motor inlet wire（13）Place, gather the real time execution electricity of motor Stream, gives Data Analysis Services module（6）；

Voltage acquisition module（2）Installed in connection box for motor（12）Interior motor inlet wire（13）Place, gather the real time execution electricity of motor Pressure, gives Data Analysis Services module（6）；

Temperature collect module（3）Installed in motor internal component（14）On, gather motor internal component（14）Real time execution temperature Degree, gives Data Analysis Services module（6）；

Rotating speed acquisition module（4）Installed in motor internal rotary part（15）Sidepiece, the real time execution rotating speed of motor is gathered, is given Data Analysis Services module（6）；

Ambient parameter acquisition module（5）Installed in housing（11）Outer surface, real time environment parameter during motor operation is gathered, is given Data Analysis Services module（6）；

Data Analysis Services module（6）Positioned at housing（11）It is interior, to the above-mentioned continuous electric current collected, voltage, temperature, turn Speed, ambient parameter data are carried out after handling in real time, with reference to from calendaring module（7）The current time information of acquisition, in memory module （8）Stored, and pass through communication module（9）With portable equipment（16）Or control centre（17）Exchange data；

Power module（10）Positioned at housing（11）Interior, its input line is from motor inlet wire（13）Place's access, electricity is provided for described device Source；

Housing（11）Shell is shielded for closed metal, passes through fixed mechanism（18）It is fixed on motor housing（19）It is upper or with electricity Machine shell（19）Integrated or and connection box for motor（12）It is integrated.

2. integrated motor intellectuality big data on-Line Monitor Device according to claim 1, it is characterised in that：Data point Analyse processing module（6）According to the motor real time execution parameter directly measured, calculate and count derivative operational factor, including power Instantaneous value and virtual value, the frequency spectrum of harmonic wave, the electricity in setting time section, voltage in setting time section, electric current, temperature occur The start-stop time of motor, number, load factor change in abnormal number and trend or feature, setting time section, and stored.

3. integrated motor intellectuality big data on-Line Monitor Device according to claim 1, it is characterised in that：Data point Analyse processing module（6）According to the real time execution parameter directly measured, and the derivative operational factor for calculating and counting, with reference to storage Module（8）In historical data, carry out motor health status diagnosis and operational factor variation tendency judge, while calculate correspondingly Characteristic parameter, the identification of failure Premonitory Characters of Doppler Radar and irregular operating state is carried out, to portable equipment（16）Or control centre（17） Send related data and warning information.

4. integrated motor intellectuality big data on-Line Monitor Device according to claim 1, it is characterised in that：Temperature is adopted Collect module（3）Including multiple temp probes, to motor internal component（14）Multiple positions simultaneously carry out temperature acquisition.

5. integrated motor intellectuality big data on-Line Monitor Device according to claim 1, it is characterised in that：Environment is joined Number acquisition module（5）Measurement motor working region ambient parameter, including environment temperature, humidity, dust concentration and air pressure, give number According to analysis and processing module（6）For assistant analysis, and stored.

6. integrated motor intellectuality big data on-Line Monitor Device according to claim 1, it is characterised in that：Communicate mould Block（9）Including close range wireless communication module（901）, remote-wireless communication module（902）With wire communication module（903）, Close range wireless communication module（901）For with portable equipment（16）Communication, remote-wireless communication module（902）For with control Center processed（17）Communication, wire communication module（903）Data are exchanged for networking between motor or with motor control assembly.

7. integrated motor intellectuality big data on-Line Monitor Device according to claim 1, it is characterised in that：The dress Putting also includes battery（20）, with power module（10）It is connected.

8. integrated motor intellectuality big data on-Line Monitor Device according to claim 1, it is characterised in that：The dress Putting all exposed parts has dust-proof, antifouling, waterproof measure.