CN216144922U - Motor state monitoring sensor and system - Google Patents
Motor state monitoring sensor and system Download PDFInfo
- Publication number
- CN216144922U CN216144922U CN202121336199.7U CN202121336199U CN216144922U CN 216144922 U CN216144922 U CN 216144922U CN 202121336199 U CN202121336199 U CN 202121336199U CN 216144922 U CN216144922 U CN 216144922U
- Authority
- CN
- China
- Prior art keywords
- motor
- data
- unit
- radio frequency
- monitoring sensor
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000012544 monitoring process Methods 0.000 title claims abstract description 71
- 230000005540 biological transmission Effects 0.000 claims abstract description 50
- 238000012545 processing Methods 0.000 claims abstract description 44
- 230000003993 interaction Effects 0.000 claims abstract description 7
- 238000003745 diagnosis Methods 0.000 claims description 17
- 230000001133 acceleration Effects 0.000 claims description 12
- 230000003595 spectral effect Effects 0.000 claims description 9
- 238000001514 detection method Methods 0.000 claims description 8
- 238000004891 communication Methods 0.000 claims description 3
- 238000006073 displacement reaction Methods 0.000 claims description 3
- 238000003306 harvesting Methods 0.000 claims description 3
- 230000006855 networking Effects 0.000 claims description 3
- 230000005236 sound signal Effects 0.000 claims description 3
- 238000012423 maintenance Methods 0.000 abstract description 27
- 238000004458 analytical method Methods 0.000 abstract description 12
- 230000015556 catabolic process Effects 0.000 abstract description 4
- 238000006731 degradation reaction Methods 0.000 abstract description 4
- 238000005096 rolling process Methods 0.000 abstract description 4
- 238000005259 measurement Methods 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 5
- 230000008054 signal transmission Effects 0.000 description 5
- 230000004913 activation Effects 0.000 description 2
- 238000004364 calculation method Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000007599 discharging Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 230000004044 response Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- QVFWZNCVPCJQOP-UHFFFAOYSA-N chloralodol Chemical compound CC(O)(C)CC(C)OC(O)C(Cl)(Cl)Cl QVFWZNCVPCJQOP-UHFFFAOYSA-N 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 230000000474 nursing effect Effects 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 238000004445 quantitative analysis Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 230000004622 sleep time Effects 0.000 description 1
- 208000024891 symptom Diseases 0.000 description 1
Images
Landscapes
- Arrangements For Transmission Of Measured Signals (AREA)
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
Abstract
The application provides a motor state monitoring sensor and system, this motor state monitoring sensor, including main control unit, radio frequency transmission module and energy acquisition system, main control unit is including the data acquisition unit that is used for gathering motor data, the data processing unit who is used for handling the motor data that data acquisition unit gathered and be used for receiving the data that data processing unit handled, carry out data interaction, receive external command and the microcontroller of configuration system parameter with radio frequency transmission module. The data acquisition unit is used for acquiring the running state data of the motor, the running state data is processed by the data processing unit, and the data is transmitted to the outside for analysis by the microcontroller through the radio frequency transmission module, so that the fault can be accurately positioned and analyzed, the fault root cause can be analyzed, the fault degradation trend can be monitored, the equipment fault can be predicted in advance, the rolling prediction of the service life of the motor can be realized, the maintenance decision is changed from temporary and unplanned maintenance into planned maintenance, and the unplanned shutdown is reduced.
Description
Technical Field
The utility model relates to a motor monitoring technology, in particular to a motor state monitoring sensor and a system.
Background
In the operation and maintenance of the motor, the monitoring and predictive maintenance of the running state of the equipment are always one of the pain points in the industry. At present, the manufacturing cost is continuously increased, the profit margin is smaller and smaller, the upgrading of the manufacturing industry is forced, and with the technical maturity of the internet of things, cloud computing and industrial big data, the online monitoring of the running state of the equipment and the prediction of the equipment fault become possible through the analysis of technical means. The main approach to reduce maintenance costs of future machines is to rely on predictive maintenance and sharing economies.
At present, most industrial motors have mechanical faults caused by bearing abrasion and unbalance, so that unexpected production stop is caused, huge losses are caused to enterprises, and the equipment is basically inspected, maintained regularly and repaired due to faults, so that the following problems exist: the maintenance personnel are more, the cost is high, and the efficiency is low; failure to find the failure symptoms in advance, and only maintenance after failure occurs, resulting in shutdown and loss; local maintenance is carried out after the fault occurs, the current problem is solved, and the root cause of the equipment fault is difficult to find; fault maintenance and planned maintenance are mainly used, and over-repair and under-repair exist; the stock spare parts have no guide information, the types, the stock quantity and the like of the spare parts cannot be determined, the production is influenced by few purchases, and the cost is excessively wasted; the actual reliability data of the equipment is lack of statistics and quantitative analysis, and the low-price and low-quality purchasing equipment of a purchasing department is difficult to know the running health state, the risk and the overall cost of the production line globally.
Disclosure of Invention
The utility model aims to provide a motor state monitoring sensor and a system which can automatically acquire motor data to realize predictive maintenance.
The following presents a simplified summary of one or more aspects in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements of all aspects nor delineate the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that is presented later.
According to an aspect of the present application, there is provided a motor state monitoring sensor including:
a master controller, the master controller comprising:
the data acquisition unit is used for acquiring motor data;
the data processing unit is used for processing the motor data acquired by the data acquisition unit; the microcontroller is used for receiving the data processed by the data processing unit, performing data interaction with the radio frequency transmission module, receiving an external command and configuring system parameters;
the data acquisition unit, the data processing unit and the microcontroller are in signal connection in sequence;
the radio frequency transmission module is used for realizing the external communication of the motor state monitoring sensor; and
the energy acquisition system is used for providing power for the whole motor state monitoring sensor;
the main controller is in signal connection with the radio frequency transmission module, and the main controller and the radio frequency transmission module are both electrically connected with the energy acquisition system.
In one embodiment, the data acquisition unit of the motor state monitoring sensor includes:
the vibration acquisition unit is used for acquiring vibration data of the motor;
the temperature acquisition unit is used for acquiring surface temperature and environment temperature data of the motor;
the magnetic field acquisition unit is used for acquiring motor magnetic field data; and
and the sound acquisition unit is used for acquiring sound signal data of the motor.
In an embodiment, the data processing unit of the motor state monitoring sensor is further configured to calculate a vibration characteristic value according to vibration data acquired by the vibration acquisition unit, where the vibration characteristic value includes: vibration frequency, acceleration peak value, velocity effective value, displacement peak value, acceleration effective value, skewness index, variance, margin factor, peak factor, kurtosis index, impulse factor, spectral variance, spectral mean, and spectral effective value.
In an embodiment, the vibration acquisition unit of the motor state monitoring sensor is further configured to acquire vibration acceleration data of the motor, and the data processing unit is further configured to calculate a triaxial inclination angle value according to the vibration acceleration data acquired by the vibration acquisition unit.
In one embodiment, the radio frequency transmission module of the motor condition monitoring sensor includes:
the information transmission unit is used for carrying out information interaction with the microcontroller;
the radio frequency processing unit is used for converting the digital signals of the information transmission unit into radio frequency analog signals and transmitting the radio frequency analog signals to the radio frequency antenna, and is also used for converting the radio frequency signals received by the radio frequency antenna into digital signals and transmitting the digital signals to the information transmission unit; and
a radio frequency antenna for transmitting and receiving radio frequency analog signals;
the information transmission unit, the radio frequency processing unit and the radio frequency antenna are in signal connection in sequence.
In one embodiment, the main controller of the motor state monitoring sensor further comprises:
the state display unit is connected with the microcontroller and is used for displaying state information of the motor state monitoring sensor, and the state information comprises one or more combinations of a startup and shutdown state, a running heartbeat state and a networking state; and
and the startup and shutdown unit is used for startup and shutdown of the motor state monitoring sensor.
In one embodiment, the motor condition monitoring sensor further comprises:
the power management module, the energy acquisition system via the power management module respectively with main control unit with the radio frequency transmission module is connected, the power management module includes:
the power supply unit is used for converting the electric energy acquired by the energy acquisition system into electric energy suitable for the main controller and the radio frequency transmission module to supply power to the main controller and the radio frequency transmission module; and
and the electric quantity detection unit is used for detecting the electric quantity of the whole motor state monitoring sensor and is in signal connection with the data processing unit of the main controller.
In one embodiment, the energy harvesting system of the motor condition monitoring sensor includes a rechargeable battery, and the power management module further includes:
a charging unit for supplying power to the rechargeable battery;
the overcharge protection unit is used for preventing the rechargeable battery from being overcharged;
an over-discharge protection unit for preventing the excessive use of the rechargeable battery; and
the over-temperature protection unit is used for monitoring the temperature of the rechargeable battery;
the charging unit, the overcharge protection unit, the overdischarge protection unit and the over-temperature protection unit are all connected with the rechargeable battery.
In an embodiment, the electric quantity detection unit of the motor state monitoring sensor is further configured to calculate the service life of the rechargeable battery according to the electric quantity data, the sensor use time and the operating frequency of the data acquisition unit.
According to another aspect of the present invention, a motor state monitoring system is further provided, which includes at least one motor state monitoring sensor described in any one of the above embodiments, and further includes an outdoor industrial base station, a cloud platform server, and an expert diagnosis platform, wherein the motor state monitoring sensor is in signal connection with the outdoor industrial base station, and both the outdoor industrial base station and the expert diagnosis platform are in signal connection with the cloud platform server.
According to another aspect of the present application, a motor state monitoring system is further provided, which includes at least one motor state monitoring sensor as described above, and further includes an outdoor industrial base station, a cloud platform server, and an expert diagnosis platform, wherein the motor state monitoring sensor is in signal connection with the outdoor industrial base station, and the outdoor industrial base station is in signal connection with the cloud platform server and the expert diagnosis platform.
The embodiment of the utility model has the beneficial effects that: the data acquisition unit is used for acquiring the running state data of the motor, the running state data is processed by the data processing unit, and the data is transmitted to the outside for analysis by the microcontroller through the radio frequency transmission module, so that the fault can be accurately positioned and analyzed, the fault root cause can be analyzed, the fault degradation trend can be monitored, the equipment fault can be predicted in advance, the rolling prediction of the service life of the motor can be realized, the maintenance decision is changed from temporary and unplanned maintenance into planned maintenance, and the unplanned shutdown is reduced.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
The above features and advantages of the present disclosure will be better understood upon reading the detailed description of embodiments of the disclosure in conjunction with the following drawings. In the drawings, components are not necessarily drawn to scale, and components having similar relative characteristics or features may have the same or similar reference numerals.
FIG. 1 is a schematic perspective view of an embodiment of a sensor of the present invention;
FIG. 2 is a functional block diagram of an embodiment of a sensor of the present invention;
fig. 3 is a schematic diagram of the connection of an embodiment of the system of the present invention.
Wherein: 1-an energy harvesting system; 2-a main controller; 3-a power management module; 4-a radio frequency transmission module; 21-a power on/off unit; 22-a microcontroller; 23-a data processing unit; 25-a status display unit; 241-a vibration acquisition unit; 242-temperature acquisition unit; 243-magnetic field collecting unit; 244 — sound collection unit; 41-a signal transmission unit; 42-a radio frequency processing unit; 43-a radio frequency antenna; 11-a rechargeable battery; 12-a power supply interface; 51-an upper housing; 52-lower housing; 6-motor state monitoring sensor; 7-outdoor industrial base station; 8-a cloud platform server; 9-expert diagnostic platform.
Detailed Description
The utility model is described in detail below with reference to the figures and specific embodiments. It is noted that the aspects described below in connection with the figures and the specific embodiments are only exemplary and should not be construed as imposing any limitation on the scope of the present invention.
For the safety of motor, stable and long period operation, carry out equipment overhaul and maintenance more scientifically to reach the target that improves equipment availability, reduce the cost of overhaul, improve operation efficiency, install long-range wireless intelligent monitoring system additional to the motor, realize intelligent monitoring equipment running state, intelligent warning screening abnormal equipment, the instant analysis and diagnosis of long-range expert, realize the intelligent service of the long-range online nurse of key part, finally realize the predictive maintenance of motor, have the reality necessity:
1) based on the big data of the motor running state, a diagnosis expert can predict equipment faults in advance, professional analysis can be carried out based on complete data, faults are accurately positioned, fault root causes are analyzed, the fault degradation trend is monitored, the rolling prediction of the service life of the motor is realized, temporary and unscheduled maintenance is converted into planned maintenance through maintenance decision, and unscheduled shutdown is reduced;
2) the workload of field personnel is reduced, and the working pressure of professional personnel is reduced. The nursing working pressure of the equipment is transferred to a background diagnostician by an equipment manager, and the professional can have more time to carry out deep research on the state of the motor;
3) and (5) evaluating the state of the motor after maintenance. After the motor is overhauled, the diagnostic expert system can independently and long-term evaluate the on-site overhauling quality through the remote wireless intelligent monitoring system, and the reliability of the motor overhauling quality is ensured.
Therefore, an embodiment of the present invention provides a motor state monitoring sensor, as shown in fig. 1 and 2, including an energy collection system 1, a main controller 2, a power management module 3, and a radio frequency transmission module 4, where the energy collection system 1 is connected to the power management module 3, and both the power management module 3 and the radio frequency transmission module 4 are connected to the main controller 2.
In a possible embodiment, the main controller 2 includes a power on/off unit 21, a microcontroller 22, a data processing unit 25 and a data acquisition unit, the data acquisition unit is connected with the data processing unit 23, the data processing unit 23 is connected with the microcontroller 22, and the power on/off unit 21 is connected with the microcontroller 22.
The microcontroller 22 is used as a control component of the main controller 2, receives data acquired by each acquisition unit processed by the data processing unit, performs data interaction with the information transmission unit 41 of the radio frequency transmission module 4 through a private protocol, sends various state data such as vibration, inclination angle, temperature, magnetic field, sound and the like to an outdoor industrial base station, and finally transmits the state data to a cloud platform server and an expert diagnosis platform; receiving various commands from a cloud platform server and an expert diagnosis platform, and configuring system parameters such as acquisition frequency, acquisition length, sleep time and the like.
The startup and shutdown unit 21 is responsible for startup and shutdown work of the whole motor state monitoring sensor, and has the modes of wireless activation, magnetic activation, button startup and shutdown and the like. The button is built-in, and false triggering is avoided. The sensor can be monitored on an expert diagnosis platform through the outdoor industrial base station wireless switch motor state.
The data acquisition unit comprises a vibration acquisition unit 241, a temperature acquisition unit 242, a magnetic field acquisition unit 243 and a sound acquisition unit 244, and the vibration acquisition unit 241, the temperature acquisition unit 242, the magnetic field acquisition unit 243 and the sound acquisition unit 244 are all connected with the data processing unit 23.
In a possible embodiment, the vibration acquisition unit 241 adopts an MEMS acceleration sensor, and can simultaneously acquire vibration data in 3 directions of the X axis, the Y axis, and the Z axis, the maximum sampling frequency is greater than 6KHz, the range is up to ± 50g, the measurement bandwidth can be realized by processing the 3-axis vibration data by the data processing unit, the measurement error is less than-1 dB within the frequency range of 1-1000 Hz, and the resolution is less than 1 mg.
In a possible embodiment, the temperature acquisition unit 242 employs a PT1000 thermal resistance temperature sensor, and can simultaneously acquire the surface temperature and the ambient temperature of the motor, accurately acquire the temperature rise data of the motor through the temperature difference between the two temperatures, and accurately determine the operation state of the motor. The surface temperature and the environment temperature of the motor acquired by the temperature acquisition unit are filtered, calculated, analyzed and the like by the data processing unit, the measurement range is as high as-50 ℃ to 300 ℃, the resolution is as high as 0.1 ℃, and the precision error is less than +/-1 ℃.
In a possible embodiment, the magnetic field acquisition unit 243 adopts a 3-axis magnetometer, the measurement range is greater than or equal to ± 30Gauss, the frequency response is up to 1000Hz, the magnetic field resolution is up to 10 mcaus after the magnetic field data acquired by the magnetic field acquisition unit is processed by filtering, calculation and the like of the data processing unit, and the measurement error is less than or equal to 100 mcaus.
In a possible embodiment, the sound collection unit 244 employs a high performance MEMS microphone sensor with a frequency response range of up to 80KHz, which may be used for ultrasonic testing. The sound detection range AOP is as high as 130dBSPL, and the signal-to-noise ratio SNR is as high as 64dB (A). After the sound signal data collected by the sound collecting unit 244 is filtered and calculated by the data processing unit, the measurement error is less than-1 dB in the frequency range of 100 Hz-10 KHz and less than-3 dB in the frequency range of 10 KHz-80 KHz.
The data processing unit 23 processes the vibration signal acquired by the vibration acquisition unit 241, and calculates vibration characteristic values such as vibration frequency, acceleration peak value, velocity effective value (vibration intensity), displacement peak value, acceleration effective value, skewness index, variance, margin factor, crest factor, kurtosis index, pulse factor, spectral variance, spectral mean value, spectral effective value and the like of 3 axes through a vibration analysis algorithm such as FFT and the like.
In addition, the data processing unit 23 processes the vibration acceleration data acquired by the vibration acquisition unit 241, and calculates the 3-axis inclination angle value measurement range of-90 degrees to +90 degrees, the resolution of 0.01 degrees and the precision error of less than or equal to 0.1 degrees through the inclination angle algorithm.
The radio frequency transmission module 4 comprises a signal transmission unit 41, a radio frequency processing unit 42 and a radio frequency antenna 43, wherein the signal transmission unit 41 is connected with the main controller 2, the radio frequency processing unit 42 is connected with the signal transmission unit 41, and the radio frequency antenna 43 is connected with the radio frequency processing unit 42.
Wherein, radio frequency transmission module 4 is responsible for the data communication between motor state monitoring sensor and the outdoor industry basic station, adopts short distance wireless transmission mode, including transmission modes such as BLE, zigBee, wiFi, loRa, LoRaWAN.
The information transmission unit 41 is responsible for information interaction with the microcontroller 22 of the main controller 2, and through its own algorithm, the stability and timeliness of transmission are ensured, the transmission rate is adjustable, and the transmission channel can be set. The transmission adopts 128-bit AES encryption, and meets the IEC62351 standard. And the remote upgrading of the firmware can be realized.
The rf processing unit 42 converts the digital signal of the information transmission unit 41 into an rf analog signal, transmits the rf analog signal through the rf antenna 43, and converts the rf signal received by the rf antenna 43 into a digital signal to transmit to the signal transmission unit 41.
The radio frequency antenna 43 is configured with different frequency bands according to different short-distance wireless transmission modes, 50-ohm impedance matching is achieved, the quality of transmission signals is guaranteed, and loss is reduced as much as possible.
The energy collection system 1 comprises a rechargeable battery 11 and a power supply interface 12, wherein the rechargeable battery 11 is connected with the power supply interface 12. The energy acquisition system 1 is responsible for the capability sources of the whole motor state monitoring sensor, and is provided with an interface processing circuit compatible with various energy sources, including battery power supply, external DC power supply, solar power supply, temperature difference power supply, CT power supply, vibration energy power supply and the like.
In a possible embodiment, the power management module 3 includes a power supply unit, a charging unit, an over-charging protection unit, an over-discharging protection unit, an over-temperature protection unit and an electric quantity detection unit, the power supply unit is electrically connected with the main controller 2 and the radio frequency transmission module 42, the charging unit is connected with the energy acquisition system 1, the electric quantity detection unit is in signal connection with the data processing unit 23, the over-charging protection unit is connected with the charging unit, the over-discharging protection unit is connected with the rechargeable battery 11, and the over-temperature protection unit is used for monitoring the temperature of the rechargeable battery 11.
Specifically, the power supply unit is responsible for supplying power to the main controller 2 and the radio frequency transmission module 4, and converts the electric energy acquired by the energy acquisition system 1 into a power supply suitable for the main controller 2 and the radio frequency transmission module 4. The charging unit is responsible for supplying power to a rechargeable battery 11 of the energy acquisition system 1, and a charging port is built in and is compatible with a wireless charging function.
The electric quantity detection unit is responsible for detecting the electric quantity of the whole motor state monitoring sensor, the detected electric quantity data are transmitted to the data processing unit of the main controller 2, the data processing unit comprehensively calculates the service life of the battery according to the electric quantity data, the service time of the sensor and the working frequency of each acquisition unit, and the calculation error of the service life is less than or equal to 5%.
The overcharge protection unit is responsible for overcharge protection work of the charging unit, and judges the current charging stage by detecting parameters such as charging voltage, charging current and the like, so as to prevent overcharge of the rechargeable battery 12.
The over-discharge protection unit is used for monitoring the use state of the battery and preventing the battery from being used excessively, particularly the rechargeable battery, which cannot be recharged after being used excessively.
The over-temperature protection unit is responsible for monitoring the temperature of the battery during use, and cuts off the power supply when the temperature of other energy source interfaces such as the battery is too high, so as to protect the internal circuit.
In a possible embodiment, the sensor further comprises a housing, a circuit board is arranged in the housing, the energy collection system 1, the main controller 2, the power management module 3 and the radio frequency transmission module 4 are all arranged on the circuit board, the power supply interface 12 is arranged on the side surface of the housing, the housing comprises an upper housing 51 and a lower housing 52, and the upper housing 51 is connected with the lower housing 52 through bolts.
In addition, the main controller 2 may further include a state display unit 25, the state display unit 25 being disposed on the upper case 51, the state display unit 25 being connected with the microcontroller 22. The state display unit 25 is responsible for the state display work of the motor state monitoring sensor, and the displayed states comprise a power-on and power-off state, a running heartbeat state, a networking state and the like.
It is easy to understand that the embodiment of the present invention further provides a motor state monitoring system, as shown in fig. 3, including at least one motor state monitoring sensor 6 as described above, further including an outdoor industrial base station 7, a cloud platform server 8, and an expert diagnosis platform 9, where the motor state monitoring sensor 6 is in signal connection with the outdoor industrial base station 7, and the outdoor industrial base station 7 is in signal connection with the cloud platform server 8 and the expert diagnosis platform 9. The motor state monitoring sensor 6 is installed on the motor, the outdoor industrial base station 7 and the motor state monitoring sensor 6 form a wireless local area network, the cloud platform server is used for obtaining the running state of the motor, storing and calculating big data, and the expert diagnosis platform is used for performing professional analysis on the data.
The expert diagnosis platform 9 is internally provided with motor intelligent operation and maintenance algorithms, including a vibration analysis algorithm, a magnetic field analysis algorithm and a sound analysis algorithm. Through comprehensive analysis of the three physical quantities, the motor start-stop and start-stop times are judged, the running time of the motor is recorded, the rotating direction of the motor is judged, and the power supply frequency of the motor is recorded. In addition, a self-learning system is arranged in the expert diagnosis platform, so that the historical trend can be automatically recorded and analyzed through self-learning, the alarm threshold value can be automatically set, and intelligent operation and maintenance can be realized. The related algorithm and software are not the main innovation points of the application, and the prior art is adopted.
The motor state monitoring sensors 6 are installed on the test points of the motor to be tested, the motor state monitoring sensors 6 in all the monitoring areas and the matched outdoor industrial base station 7 form a wireless local area network, and signal data such as vibration, temperature, magnetic fields, sound and the like detected by the motor state monitoring sensors 6 are transmitted to the outdoor industrial base station 7 in a short-distance wireless transmission mode. The outdoor industrial base station 7 stores and calculates the signal data, and transmits the effective data to the cloud platform server 8 in a 4G/5G/WAN mode. The cloud platform server 8 stores motor running state big data, and the expert diagnosis platform 9 performs professional analysis on complete motor state data on the cloud platform server 8 in a 4G/5G/WAN mode, so that faults can be accurately positioned, root causes of the faults can be analyzed, the degradation trend of the faults can be monitored, equipment faults can be predicted in advance, rolling prediction of the service life of the motor can be realized, maintenance decisions are changed from temporary and unplanned maintenance to planned maintenance, and unplanned shutdown is reduced.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.
The previous description of the disclosure is provided to enable any person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the examples and designs described herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
The above description is only a preferred example of the present application and should not be taken as limiting the present application, and any modifications, equivalents, improvements and the like made within the spirit and principle of the present application should be included in the scope of the present application.
Claims (10)
1. A motor condition monitoring sensor, comprising:
a master controller, the master controller comprising:
the data acquisition unit is used for acquiring motor data;
the data processing unit is used for processing the motor data acquired by the data acquisition unit; and
the microcontroller is used for receiving the data processed by the data processing unit, performing data interaction with the radio frequency transmission module, receiving an external command and configuring system parameters;
the data acquisition unit, the data processing unit and the microcontroller are in signal connection in sequence;
the radio frequency transmission module is used for realizing the external communication of the motor state monitoring sensor; and
the energy acquisition system is used for providing power for the whole motor state monitoring sensor;
the main controller is in signal connection with the radio frequency transmission module, and the main controller and the radio frequency transmission module are both electrically connected with the energy acquisition system.
2. The motor condition monitoring sensor of claim 1, wherein the data acquisition unit comprises:
the vibration acquisition unit is used for acquiring vibration data of the motor;
the temperature acquisition unit is used for acquiring surface temperature and environment temperature data of the motor;
the magnetic field acquisition unit is used for acquiring motor magnetic field data; and
and the sound acquisition unit is used for acquiring sound signal data of the motor.
3. The motor state monitoring sensor according to claim 2, wherein the data processing unit is further configured to calculate a vibration characteristic value according to the vibration data collected by the vibration collecting unit, and the vibration characteristic value includes: vibration frequency, acceleration peak value, velocity effective value, displacement peak value, acceleration effective value, skewness index, variance, margin factor, peak factor, kurtosis index, impulse factor, spectral variance, spectral mean, and spectral effective value.
4. The motor state monitoring sensor according to claim 3, wherein the vibration acquisition unit is further configured to acquire vibration acceleration data of the motor, and the data processing unit is further configured to calculate a triaxial tilt angle value according to the vibration acceleration data acquired by the vibration acquisition unit.
5. The motor condition monitoring sensor of claim 1, wherein the radio frequency transmission module comprises:
the information transmission unit is used for carrying out information interaction with the microcontroller;
the radio frequency processing unit is used for converting the digital signals of the information transmission unit into radio frequency analog signals and transmitting the radio frequency analog signals to the radio frequency antenna, and is also used for converting the radio frequency signals received by the radio frequency antenna into digital signals and transmitting the digital signals to the information transmission unit; and
a radio frequency antenna for transmitting and receiving radio frequency analog signals;
the information transmission unit, the radio frequency processing unit and the radio frequency antenna are in signal connection in sequence.
6. The motor condition monitoring sensor of claim 1, wherein the master controller further comprises:
the state display unit is connected with the microcontroller and is used for displaying state information of the motor state monitoring sensor, and the state information comprises one or more combinations of a startup and shutdown state, a running heartbeat state and a networking state; and
and the startup and shutdown unit is used for startup and shutdown of the motor state monitoring sensor.
7. The motor condition monitoring sensor of claim 1, further comprising:
the power management module, the energy acquisition system via the power management module respectively with main control unit with the radio frequency transmission module is connected, the power management module includes:
the power supply unit is used for converting the electric energy acquired by the energy acquisition system into electric energy suitable for the main controller and the radio frequency transmission module to supply power to the main controller and the radio frequency transmission module; and
and the electric quantity detection unit is used for detecting the electric quantity of the whole motor state monitoring sensor and is in signal connection with the data processing unit of the main controller.
8. The motor condition monitoring sensor of claim 7, wherein the energy harvesting system includes a rechargeable battery, the power management module further comprising:
a charging unit for supplying power to the rechargeable battery;
the overcharge protection unit is used for preventing the rechargeable battery from being overcharged;
an over-discharge protection unit for preventing the excessive use of the rechargeable battery; and
the over-temperature protection unit is used for monitoring the temperature of the rechargeable battery;
the charging unit, the overcharge protection unit, the overdischarge protection unit and the over-temperature protection unit are all connected with the rechargeable battery.
9. The motor state monitoring sensor according to claim 8, wherein the electric quantity detection unit is further configured to calculate the service life of the rechargeable battery according to the electric quantity data, the sensor usage time and the operating frequency of the data acquisition unit.
10. A motor condition monitoring system is characterized in that: the motor state monitoring sensor comprises at least one motor state monitoring sensor according to any one of claims 1 to 9, and further comprises an outdoor industrial base station, a cloud platform server and an expert diagnosis platform, wherein the motor state monitoring sensor is in signal connection with the outdoor industrial base station, and the outdoor industrial base station and the expert diagnosis platform are in signal connection with the cloud platform server.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202121336199.7U CN216144922U (en) | 2021-06-16 | 2021-06-16 | Motor state monitoring sensor and system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202121336199.7U CN216144922U (en) | 2021-06-16 | 2021-06-16 | Motor state monitoring sensor and system |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN216144922U true CN216144922U (en) | 2022-03-29 |
Family
ID=80802034
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202121336199.7U Active CN216144922U (en) | 2021-06-16 | 2021-06-16 | Motor state monitoring sensor and system |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN216144922U (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114740352A (en) * | 2022-06-09 | 2022-07-12 | 深圳市永达电子信息股份有限公司 | Non-contact motor fault detection method and system |
| CN115855162A (en) * | 2022-12-30 | 2023-03-28 | 南方电网数字电网研究院有限公司 | Self-energy-taking temperature and vibration sensor |
| CN116878587A (en) * | 2023-08-15 | 2023-10-13 | 中国船舶集团有限公司第七〇四研究所 | Composite signal wireless sensor based on stress wave rapid spectral kurtosis demodulation |
| CN118502330A (en) * | 2024-07-18 | 2024-08-16 | 青岛智和精密科技有限公司 | Rotary positioning control method for torque motor in swinging environment |
| CN120334734A (en) * | 2025-04-24 | 2025-07-18 | 广安职业技术学院 | A permanent magnet motor detection system, method, device and readable storage medium |
-
2021
- 2021-06-16 CN CN202121336199.7U patent/CN216144922U/en active Active
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114740352A (en) * | 2022-06-09 | 2022-07-12 | 深圳市永达电子信息股份有限公司 | Non-contact motor fault detection method and system |
| CN115855162A (en) * | 2022-12-30 | 2023-03-28 | 南方电网数字电网研究院有限公司 | Self-energy-taking temperature and vibration sensor |
| CN116878587A (en) * | 2023-08-15 | 2023-10-13 | 中国船舶集团有限公司第七〇四研究所 | Composite signal wireless sensor based on stress wave rapid spectral kurtosis demodulation |
| CN118502330A (en) * | 2024-07-18 | 2024-08-16 | 青岛智和精密科技有限公司 | Rotary positioning control method for torque motor in swinging environment |
| CN120334734A (en) * | 2025-04-24 | 2025-07-18 | 广安职业技术学院 | A permanent magnet motor detection system, method, device and readable storage medium |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN216144922U (en) | Motor state monitoring sensor and system | |
| CN203941427U (en) | The wireless field device assembly that comprises the power module with logical capability | |
| JP5075746B2 (en) | Plant monitoring system and plant monitoring method | |
| CN106471667B (en) | Integrated battery management system and method | |
| WO2020134890A1 (en) | Vibration and temperature sensor for monitoring data of safe and healthy operation of operating and rotating device | |
| CN101782629A (en) | Battery system monitoring method and device based on OBD-II | |
| CN108680244A (en) | A kind of rotating machinery vibrating wireless monitoring device and method | |
| CN111509319B (en) | PHM management system of energy storage power supply | |
| CN119044809B (en) | Lithium battery health state monitoring method and system | |
| CN112428875A (en) | Battery management system based on wireless multi-agent | |
| CN116030604A (en) | Intelligent monitoring alarm system | |
| RU120777U1 (en) | SYSTEM FOR MONITORING AND MONITORING BATTERIES OF AUTONOMOUS POWER SUPPLIES (OPTIONS) | |
| CN119906965A (en) | A low-power self-repair and energy self-supply mine dust monitoring sensor network system | |
| CN212323930U (en) | Motor intelligence fortune dimension system | |
| JP6788243B2 (en) | Agricultural machinery power system, its electric device, and agricultural machinery equipped with agricultural machinery power system | |
| CN108627278A (en) | Temperature monitoring equipment and system | |
| CN220358978U (en) | Intelligent motor vibration processing system | |
| JP2022540403A (en) | Battery diagnostic system, power system and battery diagnostic method | |
| CN116758721A (en) | Fire-fighting equipment electricity information acquisition terminal | |
| EP3618508B1 (en) | System and method for managing battery life in redundant wireless sensors | |
| CN112068006A (en) | Laboratory equipment safe operation and maintenance platform based on cloud computing | |
| CN217506140U (en) | Earthquake monitoring unit and earthquake monitoring system | |
| CN206470060U (en) | A kind of dynamic monitoring early-warning device of air cooling blower fan multiple bearing | |
| CN113534709B (en) | Oil well data acquisition and motor protection control system | |
| CN206725730U (en) | A kind of AGV power supplies on-line monitoring system |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| GR01 | Patent grant | ||
| GR01 | Patent grant |