JP5554136B2 - Monitoring system and monitoring method - Google Patents

Description

  The present invention relates to a monitoring system and a monitoring method for monitoring an operation state and a state of a plant and equipment constituting the plant.

  For the purpose of ensuring the soundness by detecting the occurrence of abnormalities in plant equipment such as the plant and the equipment and piping that make up the plant at an early stage, and appropriately responding to it and taking measures, etc. The operation status and state are constantly monitored online, or regularly monitored offline.

  For online monitoring, a detector is installed on the monitored object, and a signal cable is laid from the detector to the data collection and monitoring device installed in the central control room, etc., and the detection data of the detector is collected and monitored. Monitoring is performed by sending data to the device for storage and analysis, and remote monitoring using a telephone communication line such as PHS (Personal Handy-phone System) installed in the plant. . On the other hand, in the case of off-line monitoring, an inspector carries a portable recording terminal device and records the reading of the instrument at the site where the monitoring object is installed, or temporarily installs a detector into the portable recording terminal device. Recording is done.

  And while performing the monitoring as described above, by measuring the vibration of the device etc. and comparing the preset monitoring threshold value with the measurement data, an abnormality occurring in the device etc. is detected at an early stage. Analyzes vibration data in detail, evaluates them, analyzes the cause of abnormal events, and examines countermeasures.

  However, in online monitoring, the detector and the data collection and monitoring device are connected by a signal cable, so the range and number of monitoring are limited, the number of monitoring points is large, and a wide range of monitoring is required. When doing so, the scale of the monitoring system must be made large. In addition, when using a telephone communication line such as PHS, the original purpose is mainly for calls in a plant or the like, so the number of lines is limited, and it is not desirable to occupy data communication. In addition, in order to install a large number of detectors, there is a risk that an error may occur in the associating operation for associating the detectors with the installation locations.

  In order to solve such a point, for example, a system is considered in which a large number of data recording devices called wireless sensors each combining a sensor and a small wireless communication device are arranged, and data is collected by wireless transmission (see, for example, Patent Document 1). . Since this wireless data collection system is wireless data collection, it is not necessary to install a cable for collecting data from each sensor, and a wide range of monitoring and the number of monitoring points can be increased.

  In addition, even in offline monitoring, when there are many objects to be measured due to patrol by an inspector, a wireless sensor is installed in the equipment to be monitored in advance, so that the inspector can wirelessly It is conceivable that the recording terminal device carried by the inspector automatically receives data when approaching the sensor (see, for example, Patent Document 2).

  And most of the wireless sensors used in such monitoring use a battery as a power source, or convert external energy into a power source. In the case of a battery power source, the capacity of the battery is limited. Therefore, it is necessary to replace the battery. Also, in the case of a power source that converts external energy, it is necessary to enlarge the conversion unit in order to ensure a sufficient power source capacity, or the power generation capacity is insufficient. In order to solve such a problem, it is conceivable to use a sensor having a power saving function and a power generation function of a wireless sensor (see, for example, Patent Document 3).

JP 2005-164315 A JP 2005-308540 A JP 2008-292319 A

  As described above, the wireless sensor does not require cable laying, can be installed at low cost, and since there is no cable, there is a high degree of freedom in installation and easy installation, but there is a problem in securing the power supply, and the operation of the sensor It is considered to have power saving and power generation functions through control. However, in the vibration power generation by the vibration of the installation target device, if the vibration value of the device is small, sufficient power generation cannot be performed, and there is a possibility that a power source cannot be secured.

  Also, when considering diagnosis of equipment by vibration measurement, in order to increase the accuracy of diagnosis, increase the sampling frequency of vibration data, increase the number of bits for A / D conversion, and increase the recording time (data amount). It is desirable to do. In such a case, the electronic circuit of the wireless sensor requires an electronic component having a high processing capability. Generally, however, the power consumption of the electronic component tends to increase as the processing capability increases. It will be necessary to secure the power supply.

  On the other hand, in a monitoring system using wireless sensors, a huge number of wireless sensors can be installed, but it is possible to remotely check whether each wireless sensor is functioning normally or not. It is necessary to.

  The present invention has been made in view of such circumstances, and the object of the present invention is to reduce the power consumption of the electronic circuit in the wireless sensor and to provide power generation means, so that it is not necessary to replace the battery for the power source. It is another object of the present invention to provide a monitoring system and a monitoring method that can be continuously operated.

  The present invention achieves the above-mentioned object, and the monitoring system is a monitoring system for determining a state of the plant equipment by a monitoring device based on vibration data measured by a sensor installed in the plant equipment, and at least One or more measurement sensors for detecting and measuring the vibration of the plant equipment by providing one or more sensors, and the measurement means for receiving power supply from a power generation unit provided with a power generation means for generating power by the vibration of the plant equipment A wireless transmission / reception unit for recording and receiving vibration data recorded in the recording unit with the monitoring device based on a control signal from the monitoring device. And means for detecting vibration applied to the power generation means by providing a vibration detection sensor for detecting vibrations having a frequency lower than that of the sensor. A, and a recording apparatus to start recording the vibration data based on the measurement data of the detection means.

  The monitoring method is a monitoring method for monitoring the state of the plant equipment while operating the electronic circuit of the detecting means and the measuring means by receiving the supply of electric power generated by vibration during normal operation of the plant equipment. The vibration of the plant equipment is periodically measured by a vibration detection sensor, the measurement data of the detection means obtained by measurement is compared with a preset threshold value, and the vibration is detected when the measurement data exceeds the threshold value. By starting measurement of vibration of the plant equipment by a sensor that measures vibration at a frequency higher than that of the detection sensor, and determining the vibration data of the measuring means obtained by measurement with the sensor based on a preset determination criterion The state of the plant equipment is monitored.

  According to the present invention, in the wireless sensor, power saving of the electronic circuit can be achieved, the power generation means provided in the wireless sensor can be continuously operated, and the replacement of the battery for the power source can be made unnecessary. .

It is a block diagram which shows the monitoring system of the 1st Embodiment of this invention. It is a block diagram of the recording device in the monitoring system shown in FIG. It is a front view of the electric power generation part in the recording device shown in FIG. It is a block diagram of the modification of the recording device in the monitoring system shown in FIG. It is a front view of the electric power generation part in the modification of the recording device shown in FIG. It is a block diagram which shows the monitoring system of the 2nd Embodiment of this invention.

  Embodiments of the present invention will be described below with reference to the drawings.

(First embodiment)
First, a first embodiment of the present invention will be described with reference to FIGS. A modification of the recording apparatus according to this embodiment will be described with reference to FIGS.

  As shown in FIGS. 1 to 3, the monitoring system 1 according to the first embodiment is installed in a plant device A (not shown) to be monitored, such as a plant device A such as piping, for example, a rotating device, and measures vibration Y1. A wireless sensor is configured by at least one sensor 2 of the measuring means and at least one recording device 3 that records vibration data measured by the sensor 2.

  Further, the monitoring system 1 records information by transmitting and receiving control signals via the base station 4 to and from the base station 4 that is an information transmission device provided with a wireless transmission / reception unit (not shown) that performs wireless communication with the recording device 3. Controls the operation of the device 3 and receives input of vibration data and the like recorded by the recording device 3, and the input vibration data and the judgment criteria set in advance and stored in a storage unit (not shown) such as an alarm The monitoring device 5 is configured so as to determine the state of the plant equipment A by a determination unit (not shown) on the basis of whether the level is a certain level. The monitoring device 5 may be provided with confirmation means such as a display unit so that the inspector can confirm the determination result, the input vibration data, and the like.

  The recording device 3 constituting the wireless sensor includes a CPU (central processing unit) 6 that controls the recording device 3, vibration data recorded by the recording device 3, a preset control program, an identification ID of the recording device 3, and a recording device 3, a recording unit 7 that stores a threshold value that triggers the operation of the operation 3, a first A / D conversion unit 8 that constitutes a measurement unit that converts an analog signal of vibration Y1 measured by the sensor 2 into a digital signal, and a base station 4, a wireless transmission / reception unit 9 that performs wireless communication with the monitoring device 5 or another recording device 3, a time measuring unit 10 that manages the operation time, and a power source that supplies power for operating the recording device 3 Part 11 is provided.

  Furthermore, the recording device 3 includes a power generation unit 12 that supplies power to the power supply unit 11. The power supply unit 11 is provided with a power supply (not shown) provided with a battery or the like so that the power generated by the power generation unit 12 can be stored.

  Further, the power generation unit 12 uses, for example, a piezoelectric body 13 formed in the shape of a square bar as power generation means, and generates power by vibration of the plant equipment A. The piezoelectric body 13 has one end (root) fixed on a support base 15 provided on a sensor case 14 installed on the surface of the plant equipment A to be monitored, is attached in a one-supported beam state, and further has a free end. A weight 16 having a predetermined mass is fixed to the other end portion (tip portion).

  Furthermore, on the weight 16, a vibration detection sensor 17 as a detection means for detecting and measuring the vibration Y2 of the weight 16 is fixed. Note that the recording apparatus 3 is provided with a second A / D conversion unit 18 that constitutes a detection unit that converts an analog signal of the vibration Y2 detected and measured by the vibration detection sensor 17 into a digital signal. The sensor 2 that measures the vibration Y1 of the plant equipment A is also installed in the plant equipment A by fixing the sensor case 14 to the plant equipment A by being attached to the sensor case 14, for example.

  For the piezoelectric body 13 of the power generation unit 12, for example, in order to improve the power generation efficiency due to vibration of the plant equipment A which is a rotating equipment, for example, the vibration frequency generated during normal operation in the plant equipment A matches the natural frequency. Thus, the dimensions and the weight of the weight 16 to be fixed are adjusted. In addition, regarding the adjustment of the dimensions and the like of the piezoelectric body 13, in some cases, the vibration frequency generated when the plant equipment A is deteriorated or abnormal is grasped in advance so that the vibration frequency and the natural frequency coincide with each other. In addition, the deterioration and abnormality of the plant equipment A may be clarified.

  For the base station 4, in addition to a wireless transmission / reception unit (not shown), although not shown, a control signal for controlling the operation of the recording device 3 between the monitoring device 5 and the recording device 3 and vibration data recorded by the recording device 3. To temporarily store a transmission / reception unit for transmitting and receiving a program, a program for controlling operations such as wireless communication, an identification ID for identifying the base station 4, vibration data to be communicated, and information on the recording device 3 As well as the recording device 3, and a timer for managing the operation time.

  The monitoring by the monitoring system 1 configured in this way is, for example, a form that can be integrated or integrated, for example, so that an inspector can first carry and move for monitoring. Then, the base station 4 and the monitoring device 5 that are capable of carrying both of them simultaneously are carried and moved to the monitoring area. The base station 4 and the monitoring device 5 have a built-in power source such as a battery so that they can be carried.

  When the inspector carries the base station 4 and the monitoring device 5 and moves to enter a range where wireless communication between the base station 4 and the recording device 3 is possible, communication between the base station 4 and the recording device 3 is performed. It is performed automatically or manually, and transmission / reception of control signals output from the monitoring device 5 and vibration data recorded by the recording device 3 are transmitted / received. Based on the vibration data and the like obtained in this manner, the monitoring device 5 determines the state of the plant equipment A.

  In addition, with the base station 4 and the monitoring device 5 installed in a central control room or office of the plant or the like, the wireless communication capability of the base station 4 is increased by using an external power source, and the communicable range is expanded. As long as it can be covered, the state of each plant equipment A can be determined from a remote location by concentrating each vibration data etc., and the operation schedule of the plant or each plant equipment A can be determined. Based on this, the state of each plant device A can be grasped.

  The functions of the sensor 2 that is installed in the plant equipment A and measures the vibration Y1 of the plant equipment A and the vibration detection sensor 17 that measures the vibration Y2 of the weight 16 fixed to the piezoelectric body 13 are, for example, two types of vibrations. The case where the vibration monitoring of the rotating equipment of the plant equipment A is performed using the sensor 2 for measurement and the vibration detection sensor 17 will be described.

  In general, in rotating equipment, vibration is generated by the rotation of the shaft, but it is known that the vibration level and the generated vibration frequency change due to changes in the bearing, rotating shaft, and other support conditions. Abnormality is detected using a vibration meter. The vibration frequency may be up to several hundred Hz, but measurement up to several tens of kHz is required for detecting deterioration of the rolling bearing. In order to measure vibrations of several tens of kHz and make a high-precision diagnosis, a sensor and an A / D converter that can handle this frequency are required, and electronic components with relatively high power consumption are used. Since the A / D converter is operated, the power consumption increases.

  In such a situation, in order to detect an increase in the vibration of the plant equipment A, a sensor capable of detecting a low frequency of about 1 kHz which requires relatively little power consumption of the A / D converter is used as the vibration detection sensor 17. . The sensor 2 that measures the vibration Y1 for determining the state of the plant equipment A uses a sensor that measures vibrations of several tens of kHz, which is a frequency higher than the frequency detected by the vibration detection sensor 17, and A / As the D converter, the first A / D converter 8 whose power consumption is larger than that of the second A / D converter 18 used for the vibration detection sensor 17 is used.

  That is, the increase in vibration of the plant equipment A is detected by the detection means of the vibration detection sensor 17 and the second A / D converter 18 that detect a low frequency that requires relatively little power consumption. The vibration is measured by the sensor 2 capable of measuring a high frequency with higher power consumption than the detection means and the measurement means of the first A / D converter 8.

  The process of determining the state of the plant equipment A is first performed by the vibration detection sensor 17 of the detecting means fixed to the weight 16 fixed to the tip portion of the piezoelectric body 13 that is likely to vibrate and installed in the plant equipment A. The vibration Y2 during normal operation of A is periodically measured according to the set program.

  Next, the measurement data of the vibration detection sensor 17 periodically measured is converted into an analog signal by the second A / D conversion unit 18 constituting the detection means, and is stored in the recording unit 7 of the recording device 3. The stored threshold value is compared with a comparison unit (not shown), and if the measurement data does not exceed the threshold value, the measurement is continued as it is. When the measurement data exceeds the threshold value, the vibration Y1 of the plant equipment A is measured by the sensor 2 of the measuring means.

  Further, the vibration data of the vibration Y1 measured by the sensor 2 is input to the recording device 3 and the analog signal is converted into a digital signal by the first A / D conversion unit 8 constituting the measuring means, together with the recording start time. Recorded and stored in the recording unit 7. The recording unit 7 also stores vibration data when the peak value of vibration data of the vibration Y1 and the peak value among a plurality of inputs become maximum. The stored vibration data and the like are output to the monitoring device 5 via the base station 4 by wireless communication. And in the monitoring apparatus 5, a judgment part judges the state of the plant equipment A based on the input vibration data and the judgment criteria preset and memorize | stored in the memory | storage part.

  The power consumed by the recording device 3 for monitoring the state of the plant equipment A is the power generated by the piezoelectric body 16 that is the power generation means of the power generation section 12 due to vibration during normal operation of the plant equipment A. It is supplied while being stored in a power source such as a battery.

  As described above, this embodiment is configured, the sensor 2 and the recording device 3 are installed in the plant equipment A to be monitored, and the power generated by the power generation means of the power generation unit 12 is supplied by vibration during normal operation of the plant equipment A. Thus, the measurement data measured by the vibration detection sensor 17 is compared with the measurement data measured by the vibration detection sensor 17 of the detection means that regularly checks the vibration of the plant equipment A with low power consumption. When the value exceeds the threshold value, the vibration Y1 of the plant equipment A is measured by the sensor 2 of the measuring means, and vibration data is recorded and stored. For example, an inspector carries the base station 4 and the monitoring device 5 wirelessly. If communication is possible, information is transmitted and received between the recording device 3 and the monitoring device 5 via the base station 4, and the state of the plant equipment A is determined by the monitoring device 5 as vibration data of vibration Y1. Since to be done by the judgment based on the criteria, the sensor 2, it is possible to reduce the power consumption of the wireless sensor constituted by recorder apparatus 3. In addition, the power supply required for monitoring the state of the plant equipment A can be performed without using a battery or an external power source that requires replacement. The vibration data of the plant equipment A is always recorded and stored, and the operating status of the plant equipment A At the same time, it is possible to easily monitor the state.

  In addition, in order to calibrate the sensor 2 and the vibration detection sensor 17 in this embodiment, you may comprise like the modification shown in FIG.4 and FIG.5.

  That is, the recording device 3a includes a voltage input unit 19 that generates a vibration Y in the piezoelectric body 13 in response to a control signal from the monitoring device 5 as vibration generating means, and calibration of the sensor 2 and the vibration detection sensor 17 is first performed. This is performed by transmitting a voltage input operation control signal for performing a voltage input operation from the monitoring device 5 to the recording device 3 a via the base station 4. In the recording device 3a that has received the voltage input operation control signal, the voltage input unit 19 applies a predetermined calibration voltage to the piezoelectric body 13 based on the received voltage input operation control signal, and the calibration vibration Y is applied to the piezoelectric body 13. Wake up.

  When the piezoelectric body 13 vibrates with the vibration Y for calibration, the vibration detection sensor 17 outputs measurement data corresponding to the vibration Y, and the sensor 2 also outputs corresponding vibration data. Each output data is A / D converted by the first A / D conversion unit 8 and the second A / D conversion unit 18, recorded and stored in the recording unit 7, and further from the wireless transmission / reception unit 9. Is transmitted and transmitted to the monitoring device 5 via the base station 4.

  The monitoring device 5 confirms the vibration waveform of the transmitted corresponding measurement data and vibration data, and confirms whether or not the sensors 2 and 17 are operating normally. At this time, the vibration signal level generated by the voltage signal input to the sensor 2 or the vibration detection sensor 17 is measured in advance and stored as the reference vibration signal level, so that the reference vibration signal level obtained in advance is stored. By comparing the vibration signal levels obtained by this measurement with each other, it is possible to confirm whether or not there is a sensitivity change in both sensors 2 and 17. If there is a change in the signal level in the confirmation of the presence or absence of this sensitivity change, the sensor that has changed can be calibrated by adding correction so that it becomes the reference vibration signal level obtained in advance. The automatic sensor calibration can be performed based on the stored reference vibration signal level.

  As described above, by configuring as in the present modification, the same effects as in the above-described embodiment can be obtained, and the presence or absence of sensitivity change of the sensor 2 and the vibration detection sensor 17 can be confirmed and calibrated. it can.

  In this embodiment, only the sensor 2 that measures the vibration Y1 is provided. However, in order to determine the state of the plant equipment A, other sensors that measure temperature, pressure, and the like may be installed. Good.

(Second Embodiment)
Next, a second embodiment of the present invention will be described with reference to FIG. In addition, the same code | symbol is attached | subjected to the part same as 1st Embodiment, description is abbreviate | omitted, and the structure of this embodiment different from 1st Embodiment is demonstrated.

  As shown in FIG. 6, the monitoring system 21 of the second embodiment is installed in a plant device A of a plant (not shown) that is a monitoring target, and is normally operated by the sensor 2 that measures the vibration Y1 and the vibration detection sensor 17. A recording device 3 that periodically measures vibration Y2 and records and stores vibration data measured by the sensor 2 when the measured data exceeds a threshold value, and a base station 4 that performs wireless communication with the recording device 3, The monitoring device 5 that determines the state of the plant equipment A by comparing the vibration data and the like recorded by the input recording device 3 with the determination criteria, and the vibration data and the like are transmitted by connecting at least one base station 4 and the monitoring device 5. For example, a communication line 22 such as a wired LAN (Local Area Network) in the plant is provided.

  In the monitoring system 21 configured as described above, a plurality of base stations 4 share a range in which a plurality of wireless communications can be performed, and a plurality of base stations 4 are connected to a connection portion of the communication line 22 in each range, thereby The vibration data of the corresponding plant equipment A obtained from the recording device 3 is transmitted and concentrated on one monitoring device 5. The monitoring device 5 can determine the transmitted vibration data and the like based on the determination criteria, and monitor the state together with the operation status of each plant device A.

  As a result, the present embodiment can achieve the same effects as those of the first embodiment, and can be concentrated in the plant by one monitoring device 5 without increasing the wireless communication range of the base station 4. The operation status and state of each plant equipment A can be monitored.

DESCRIPTION OF SYMBOLS 1,21 ... Monitoring system, 2 ... Sensor, 3, 3a ... Recording apparatus, 4 ... Base station, 5 ... Monitoring apparatus, 6 ... CPU, 7 ... Recording part, 8 ... 1st A / D converter, 9 ... Wireless transmission / reception unit, 10 ... Timekeeping unit, 11 ... Power supply unit, 12 ... Power generation unit, 13 ... Piezoelectric body, 14 ... Sensor case, 15 ... Support base, 16 ... Weight, 17 ... Vibration detection sensor, 18 ... Second A / D converter, 19 ... voltage input unit, 22 ... communication line

Claims (11)

Based on vibration data measured by a sensor installed in the plant equipment, a monitoring system for judging the state of the plant equipment by a monitoring device,
Measuring means for detecting and measuring vibration of the plant equipment by providing at least one or more sensors;
A recording unit that receives power supplied from a power generation unit provided with a power generation unit that generates power by vibration of the plant equipment and records vibration data measured by the measurement unit, and the monitoring device The power generation unit includes a wireless transmission / reception unit that transmits / receives vibration data recorded in the recording unit by wireless communication based on a control signal from a device, and includes a vibration detection sensor that detects vibrations having a lower frequency than the sensor. A monitoring system comprising: a detecting unit that measures vibration applied to the recording unit, and a recording device that starts recording vibration data based on measurement data of the detecting unit.   2. The monitoring system according to claim 1, wherein the power generation means is a piezoelectric body, and a natural frequency of the piezoelectric body is equal to a vibration frequency generated by the operation of the plant equipment.   3. The monitoring system according to claim 1, wherein the power generation means is a piezoelectric body, and a natural frequency of the piezoelectric body is equal to a vibration frequency generated when the plant equipment is abnormal.   When the vibration detection sensor installed in the power generation means detects vibration exceeding a preset threshold for detecting abnormality of the plant equipment, vibration data obtained by measuring the vibration of the plant equipment by the sensor is used. The monitoring system according to claim 1, wherein the monitoring system is recorded in a recording unit.   When the vibration detection sensor detects vibration exceeding a preset threshold for detecting an abnormality of the plant equipment, the recording unit holds the recording start time of vibration data and the peak value of vibration data, The monitoring system according to any one of claims 1 to 4, wherein vibration data when a peak value among a plurality of inputs becomes maximum is held in the recording unit. The monitoring system according to any one of claims 1 to 3, wherein vibration of the plant equipment is recorded in the recording device based on an operation schedule of the plant or the plant equipment.   A base station that performs wireless communication between the monitoring device and the recording device is provided, and the recording device relays the base station and transmits information to other recording devices by wireless communication. The device monitoring system according to any one of claims 1 to 6.   The monitoring system according to claim 1, wherein the recording device includes a vibration generating unit that generates vibration in the power generation unit.   8. The vibration generated by the vibration generating means is measured by the sensor or the vibration detection sensor, and the operation of the sensor or the vibration detection sensor is confirmed. Monitoring system.   The vibration generated by the vibration generating means is measured by the sensor or the vibration detection sensor, and each vibration signal level recorded by the sensor or the vibration detection sensor is compared with a reference vibration signal level prepared in advance. The monitoring system according to claim 9, wherein the sensor or the vibration detection sensor is calibrated. A monitoring method for monitoring the state of the plant equipment while operating the electronic circuit of the detection means and the measurement means by receiving supply of electric power generated by vibration during normal operation of the plant equipment,
The vibration of the plant equipment is periodically measured by a vibration detection sensor, the measurement data of the detection means obtained by measurement is compared with a preset threshold value, and when the measurement data exceeds the threshold value, the vibration detection sensor By starting measurement of vibration of the plant equipment by a sensor that measures vibration of higher frequency, and determining the vibration data of the measuring means obtained by measuring with the sensor based on a predetermined criterion, the plant A monitoring method characterized by monitoring the state of a device.

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