WO2020134890A1

WO2020134890A1 - Vibration and temperature sensor for monitoring data of safe and healthy operation of operating and rotating device

Info

Publication number: WO2020134890A1
Application number: PCT/CN2019/122515
Authority: WO
Inventors: 沈新荣; 徐华锋; 柴秋子; 付立; 李创; 许丹丹
Original assignee: 杭州哲达科技股份有限公司
Priority date: 2018-07-30
Filing date: 2019-12-03
Publication date: 2020-07-02
Also published as: CN109655106A; CN109813422A; CN109682461A

Abstract

A vibration and temperature sensor for monitoring data of safe and healthy operation of an operating and rotating device, comprising a housing for packaging; a triaxial vibration sensing module, a temperature monitoring module, a filtering module, a data processing module, a wireless communication module and a battery module are provided in the housing, the triaxial vibration sensing module is sequentially connected to the filtering module and the data processing module by means of signal lines, the temperature monitoring module and the wireless communication module are respectively connected to the data processing module by means of signal lines, and the battery module is used for supplying power to various components. The vibration sensor has a high integration level, is convenient to mount, and is able to directly output a vibration speed effective value, a triaxial vibration waveform diagram and a frequency spectrum diagram. If the vibration and temperature sensor is further used to build up a safety and health monitoring system of an operating/rotating device, the whole process is simple and easy to operate.

Description

Vibration temperature sensor used for monitoring health data of running equipment

Technical field

The invention belongs to the field of intelligent control, and in particular relates to a vibration temperature sensor used for the monitoring of the operating data safety of the operating equipment, which is mainly used for monitoring the operating data of the operating equipment.

Background technique

Operating equipment includes operating equipment and rotating equipment, which are widely used in daily production and life.

For example, the car frame of the equipment car is a supporting frame of the car body, which is composed of a cross beam, a column, a bottom beam and a diagonal rod. The car body is composed of a car bottom, a car wall, a car top and lighting, a ventilation device, a car decoration and a control button board in the car. The equipment car is the part of the car body that is in direct contact with people or goods, and it is particularly important to maintain safe operation.

During the operation of the equipment, it mainly depends on the traction machine to transmit and transmit power and drive. The traction machine is the power equipment of the equipment, also known as the host of the equipment, including the motor, coupling, brake, reducer, machine base, and traction wheel. Several main components. Equipment accidents occur frequently, most of which are due to problems with various parts of the traction machine and cannot work normally. The traction machine is not well monitored and diagnosed.

Machine pumps usually include fans, water pumps, compressors, steam turbines, and other large and small rotating machinery. They are the key production equipment in modern enterprises such as petroleum, chemical, metallurgy, steel, and power. The running condition of the machine pump directly affects the efficiency of the company's production. It can even cause safety problems when the failure is serious. Through real-time monitoring and diagnostic analysis of the machine pump, the early signs of the machine pump failure can be found in time to avoid And reduce the occurrence of major production accidents, thereby effectively extending the operating life of the pump, reducing maintenance costs, and achieving safety and efficiency throughout the life cycle of the pump.

Various industries such as petroleum, chemical, automobile, etc. use a large number of motors as prime movers to drive various production machinery. However, the vibration of the motor has the following hazards: it consumes energy and reduces the efficiency of the motor; it directly damages the motor bearing and accelerates the wear of the motor bearing, which greatly shortens the normal life of the bearing; loosening the rotor magnetic poles, causing the stator and rotor to rub against each other, resulting in The rotor of the motor bends or breaks; loosen the wire binding at the end of the motor, causing the end windings to rub against each other, reduce the insulation resistance, shorten the insulation life, and cause insulation breakdown in severe cases; affect the operation of the foundation or other equipment supporting the motor. It caused some parts to loosen, and even caused some parts to be damaged due to fatigue, resulting in accidents.

At present, there is no vibration temperature sensor that can be simply and practically used for monitoring the operating data of the operating equipment.

Summary of the invention

The technical problem to be solved by the present invention is to overcome the shortcomings in the prior art and provide a vibration temperature sensor for the safe monitoring of the operating data of the operating equipment.

To solve the technical problem, the solution of the present invention is:

To provide a vibration temperature sensor for the monitoring of the running data of an equipment, including a housing for packaging; a triaxial vibration sensing module, a temperature monitoring module, a filtering module, a data processing module, and a wireless communication module are built in the housing It is connected to the battery module and the three-axis vibration sensing module through the signal line in order to connect the filter module and the data processing module. The temperature monitoring module and the wireless communication module are connected to the data processing module through the signal line. The battery module is used to supply power to each component.

In the present invention, a switch module is provided on the casing, and the switch module is connected to the data processing module through a signal line.

In the present invention, a magnetic base module is provided at the bottom of the housing, which is used for fixed installation by magnetic attraction.

In the present invention, the battery module is a lithium battery with a charging interface.

In the present invention, the wireless communication module is a LoRa communication module, a Wi-Fi communication module or an NB-IOT communication module.

In the present invention, the calculation software module embedded in the data processing module is used to convert the vibration acceleration data collected by the triaxial vibration sensing module into the effective value of the vibration speed, and output the triaxial vibration through Fourier transform Waveform and spectrogram.

Compared with the prior art, the beneficial effects of the present invention are:

1. The vibration temperature sensor of the present invention has a high degree of integration, is easy to install, and can directly output the temperature value, the effective value of the vibration speed, the triaxial vibration waveform diagram and the frequency spectrum diagram; if the vibration temperature sensor is further used to build the operation/rotation equipment Ankang monitoring system, the whole process is simple and easy to operate.

2. The invention can be used for real-time monitoring of vibration and temperature data during the operation of running equipment, which is convenient for finding early signs of equipment failure in time and avoiding and reducing the occurrence of major accidents. This can effectively extend the operating life of the equipment, reduce maintenance costs, and ensure the safety and efficiency of the equipment throughout its life cycle.

3. The present invention has a built-in wireless communication module, which uses wireless communication to realize the data transmission of the vibration temperature sensor with low cost, high accuracy, and long transmission distance, making Ankang monitoring more convenient and low-cost.

BRIEF DESCRIPTION

FIG. 1 is a schematic diagram of the principle of the vibration temperature sensor in the present invention.

Fig. 2 is a schematic diagram of the principle of an Ankang monitoring system using a vibration temperature sensor.

detailed description

In order to make the objectives, technical solutions, and advantages of the present invention clearer, further detailed descriptions are given in conjunction with the accompanying drawings. It should be understood that the specific embodiments described herein are only intended to explain the present invention, and are not intended to limit the present invention.

First of all, it should be noted that the present invention belongs to signal detection technology, and relates to the application of computer technology in the field of industrial production. In the specific implementation or application process introduced by the present invention, the application of multiple software function modules will be involved. The applicant believes that, after carefully reading the application documents and accurately understanding the implementation principles and objectives of the present invention, those skilled in the art can fully use the software programming skills they master to implement the present invention in combination with the existing well-known technology. The aforementioned software functional modules include, but are not limited to: computing software modules embedded in data processing modules, operating equipment fault knowledge base, Ankang management and control cloud platform, analysis and diagnosis algorithm software modules, visual output software modules, etc. Are in this category, and applicants will not list them one by one.

The vibration temperature sensor of the present invention includes a housing for packaging (such as a 304 stainless steel housing), and a triaxial vibration sensing module, a temperature monitoring module, a filtering module, a data processing module, a wireless communication module, and a battery module are built in the housing. The three-axis vibration sensing module is connected to the filtering module and the data processing module in sequence through the signal line, the temperature monitoring module and the wireless communication module are respectively connected to the data processing module through the signal line, and the battery module is used to supply power to each component.

In the vibration temperature sensor, the three-axis vibration sensor module is used to realize the real-time monitoring of the acceleration signals of the three axes (X axis, Y axis, Z axis) of the running equipment. The MEAS 7131A-0050 three axis produced by TE Connectivity in the United States can be selected. Vibration acceleration chip. The temperature monitoring module is used to realize real-time monitoring of the surface temperature of the running equipment; the filter module conforms to the ISO10816 vibration level standard, and has anti-aliasing function, which can automatically filter out the low-frequency noise signals below 10Hz in the environment and improve the accuracy of vibration signal monitoring ; The battery module can be selected with a lithium battery with a charging interface, which is used to supply power to various components in the vibration temperature sensor, and the life span is up to 4-5 years; the magnetic base module enables the vibration temperature sensor to be fixed on the running equipment by magnetic attraction (It can also be fixed with glue). A switch module is provided on the casing of the vibration temperature sensor, and the switch module is connected to the data processing module through a signal line. The control object of the switch module can have multiple choices, for example, it can control the switching state of the vibration temperature sensor (power on and off operation), and can also control whether to participate in the network operation of multiple vibration temperature sensors (single machine operation or group Network operation switching operation).

The data processing module is a processor chip with computing power, and can select common single chip microcomputer, CPU and so on. The calculation software module is embedded in the data processing module, which is used to convert the vibration acceleration data collected by the triaxial vibration sensing module into the effective value of the vibration speed, and output the triaxial vibration waveform diagram and spectrum diagram through the Fourier transform. The process of data conversion and transformation belongs to the prior art. Among them, for the method of conversion to the effective value of the vibration speed, please refer to the patent document "The Numerical Calculation Method of the Effective Value of the Total Vibration Speed of the Aero Engine" published in June 2013; the conversion output is the triaxial vibration waveform and frequency spectrum For the method, please refer to the paper published in the February 2013 "Partial Vibration of Planetary Gearbox Gears". A person skilled in the art can complete the corresponding calculation according to his mastered skills and actual needs.

The following example illustrates the process of converting the vibration acceleration value into the vibration speed effective value:

First, the wavelet transform is used to preprocess the vibration acceleration data, and then the effective value of the vibration speed is obtained by integral calculation;

Integrate the vibration acceleration signal a(t) to obtain the vibration velocity value v(t), as shown in formula (1):

Among them, t is the time of data collection;

According to the vibration speed value v(t), the effective value of vibration speed vrms is obtained, as in formula (2):

Among them, T is the vibration period.

The vibration temperature sensor of the present invention is used to monitor the Ankang operation data of the running equipment, but it does not involve the analysis of the Ankang operation state and fault conditions. In order to facilitate the understanding of the present invention, a further application method of the vibration temperature sensor will be described below.

Vibration temperature sensor can be used to build an equipment health monitoring system with database server and cloud server to achieve the purpose of equipment health monitoring. Multiple vibration temperature sensors are installed on the running equipment, and data transmission is realized with the database server through wireless communication, and the database server is connected to the cloud server through a cable.

The database server is installed in the control center of the equipment room, and has a built-in knowledge base of operating equipment faults; at the same time, it also receives and stores the data collected by the vibration temperature sensor (and video camera) to provide a data basis for fault analysis and diagnosis of operating equipment, and can also be used at any time. Call up historical data for viewing.

In the present invention, the wireless communication module can be selected according to the field device installation and database server configuration. Any wireless communication module that can be used for wireless data transmission can be used in the present invention, such as LoRa communication module, Wi-Fi communication module or NB- IOT communication module. According to different choices of wireless communication modules, the corresponding wireless communication transmission mode will also be adjusted accordingly. For example: (1) A LoRa wireless gateway is installed between the vibration temperature sensor and the database server, and the LoRa communication module performs data transmission with the wireless receiving module installed in the database server through the LoRa wireless gateway; (2) The Wi-Fi communication module and The wireless receiving module installed in the database server directly transmits data (within a short distance); or, a Wi-Fi wireless gateway is installed between the vibration temperature sensor and the database server, and the Wi-Fi communication module uses Wi-Fi wireless The gateway performs data transmission (within a longer distance) with the wireless receiving module installed in the database server; (3) The NB-IOT communication module directly transmits data with the wireless receiving module installed in the database server.

The LoRa wireless communication method is a low-power, long-distance WAN communication method, with ultra-high data reception sensitivity and super strong signal-to-noise ratio. The Wi-Fi wireless communication method is a close-range, high-precision communication method that can achieve a sampling rate of 128K. The NB-IOT wireless communication method is a low-power long-distance WAN communication method, without the need to deploy a base station, and can achieve long-term data transmission every 20 seconds at the shortest. LoRa wireless gateway and Wi-Fi wireless gateway can further realize data transmission with database server through wireless communication (such as 4G, 5G, etc.).

The cloud server is installed in the building's general control room, built-in Ankang management and control cloud platform, and equipped with human-computer interaction equipment; the platform is equipped with the platform with analysis and diagnosis algorithm software module and visual output software module. The analysis and diagnosis algorithm software module performs data perception on a large amount of data collected by the vibration temperature sensor, and analyzes and obtains the effective value of the overall vibration speed of the operating equipment and the operating temperature data. Then compare with the vibration intensity level and operating temperature level of the running equipment stored in the running equipment fault knowledge base to conduct health analysis and safety diagnosis of the equipment. While displaying the results in real time through the visual output software module, real-time warnings or alarms are issued according to preset fault conditions. Based on the Ankang cloud platform for control and wired and wireless (such as 4G, 5G, etc.) communication, users of the platform can realize intelligent monitoring and control through mobile terminals such as mobile phones, tablets, and computers, or communicate with platform-based visual software.

The operating equipment fault knowledge base is a large knowledge base that can be composed of multiple components. For example: (1) The vibration intensity data and spectrum characteristics of different types of product components of different types of operating equipment under different usage conditions can be aggregated and classified, that is, they can be built into vibration data components of operating equipment components; (2) Standard ( Such as the ISO2372 vibration standard) the overall vibration speed intensity level range to construct the vibration intensity data component; (3) the standard (such as JB/T5294-91 temperature standard) specified operating temperature level range to construct the temperature data component; (4) history The fault records covered by big data, as well as the integration of mass operating equipment fault examples, constitute a knowledge base component; this component can cover most of the possible operating equipment faults and their detection methods, which are divided into mechanical faults, electrical faults, installation irregularities, There are several major categories such as inadequate maintenance, product component failure, improper use failure and so on.

By installing a video camera on the running equipment (for example, in the center of the top of the car), the working status of the running equipment can be monitored 360° in all directions. The video data collected by the video camera is wirelessly transmitted to the database server for storage, and can be called by the Ankang management cloud platform built into the cloud server. The combination of the video data of the camera and the analysis results of the temperature and vibration signal of the vibration temperature sensor can fully guarantee the accuracy and reliability of the diagnostic analysis.

The method for applying the vibration temperature sensor of the present invention to the monitoring of the health of running equipment includes the following steps:

(1) Install multiple vibration temperature sensors on the running equipment;

For example: for the elevator car, there are four vibration temperature sensors, which are respectively installed on the four top corners of the elevator car; for the elevator traction machine, there are three vibration temperature sensors, which are respectively installed in the traction The left end of the base of the machine, the right end of the base of the traction machine, and the bearing end bracket of the traction machine; for the pump, there are two vibration temperature sensors, which are respectively installed on the bearing end and the base end of the pump; As far as the motor is concerned, there are two vibration temperature sensors, which are respectively installed on the casing of the motor main body and the support member of the transmission shaft relative to the distal direction of the motor main body.

Use the three-axis vibration sensor module built in the vibration temperature sensor to obtain the vibration acceleration signal and temperature signal; after the filter module eliminates the clutter, the data processing module converts the acceleration data into the effective value of the vibration velocity, the vibration waveform diagram and the spectrum diagram ; The wireless communication module transmits the source data and the converted data to the database server for storage through wireless communication transmission;

(2) The database of the running equipment fault is built into the database server, and the Ankang cloud platform is built into the cloud server. The platform is equipped with software modules for analysis and diagnosis algorithms and software modules for visual output;

The analysis and diagnosis algorithm software module extracts the data stored in the database server and calculates it to obtain the effective value of the overall vibration speed and operating temperature of the operating equipment; after analysis and comparison with the data in the operating equipment fault knowledge base, health analysis and safety are obtained Diagnosis results; while displaying the results in real time through the visual output software module, real-time warnings or alarms are issued according to preset fault conditions.

The analysis and comparison described in step (2) specifically include:

(2.1) Analysis and comparison of the overall vibration speed of running equipment

After analyzing and diagnosing the algorithm software module to extract the data, the effective value of the vibration speed obtained by each vibration temperature sensor is weighted according to a predetermined rule to obtain the overall vibration speed of the running equipment; then it is combined with the running equipment vibration in the running equipment fault knowledge base Compare the values corresponding to the intensity level to obtain the health level of the overall vibration speed of the operating equipment;

(2.2) Analysis and comparison of operating temperature of operating equipment

After analyzing and extracting the data from the software module of the diagnostic algorithm, the temperature values obtained by the vibration temperature sensors are weighted according to the predetermined rules to obtain the overall operating temperature value of the operating equipment; then it is combined with the operating temperature of the operating equipment in the knowledge base of the operating equipment fault Compare the values corresponding to the levels to obtain the health level of the overall operating temperature of the operating equipment;

(2.3) Analysis and comparison of vibration spectrum characteristics of various components of running equipment

In the diagnosis result obtained in step (2.1) or (2.2), as long as the health level of any of the overall vibration speed or operating temperature of the operating equipment belongs to the maintenance that should be shut down, the analysis and diagnosis algorithm software module will further analyze the vibration waveform and Extract and analyze the vibration spectrum characteristics of each component of the operating equipment in the spectrum diagram; then compare the analysis results with the spectrum characteristics of each component of different health levels summarized in the operating equipment fault knowledge base, and the visualization output software module displays the comparison results in real time For reference by maintenance personnel.

Among them: for the elevator car, the components for spectrum characteristic comparison refer to the car frame, the car body and the car door; for the elevator traction machine, the components for spectrum characteristic comparison refer to the motor , Couplings, brakes, reducers, bases and traction wheels; for pumps, the components that perform spectral characteristic comparison refer to the base, rotor, sliding bearings, gearbox and impeller; for motors The components that compare the spectral characteristics refer to the magnetic pole, rotor, commutator, brush, housing, bearing and transmission shaft.

Application examples of the health monitoring methods for operating equipment:

1. According to the overall vibration speed of the operating equipment, the vibration intensity can be divided into four different levels of A, B, C, and D; among them, Area A means that the operation is in good condition without any fault problems (health); Area B It indicates that there is a slight vibration during operation, which is the allowable value during operation, and no maintenance is required (healthy, continuous observation is required); Area C indicates that there is obvious vibration during operation. It is recommended to query the cause of the failure through the operation equipment fault knowledge base. (Sub-health, it is recommended to carry out corresponding maintenance); Area D indicates that there is severe vibration during operation, and the operation of the equipment must be stopped immediately for emergency maintenance (failure, analysis of the vibration spectrum characteristics of related components is required).

2. According to the different operating temperatures of the operating equipment, the operating temperature can be divided into four different grade ranges of A, B, C, and D; among them, area A indicates that the operating condition is good and there is no failure problem (health); area B indicates There is a slight temperature rise during operation, which is the allowable value during operation and does not require maintenance (healthy, continuous observation is required); Area C indicates that there is a significant temperature increase during operation. It is recommended to query the cause of the failure through the operating equipment failure knowledge base Analysis (sub-health, it is recommended to carry out corresponding maintenance); Area D indicates that there is a rapid temperature rise during operation, and the equipment must be stopped immediately for emergency maintenance (failure, analysis of the vibration spectrum characteristics of related components is required).

3. Analysis and comparison of vibration spectrum characteristics of various components of running equipment

Due to the difference in materials and shapes, each component of the running equipment has a different range of fixed vibration spectrum characteristics. Different operating states will show different vibration spectrum characteristics in the vibration waveform diagram and spectrum diagram; The vibration spectrum characteristics of the healthy operating equipment are detected under normal operation, and the massive fault spectrum characteristics of the operating equipment tracked by field applications such as literature and projects are collected to form a database component of the knowledge base. By comparing and analyzing the vibration spectrum characteristics obtained from the analysis with the knowledge base, the failure type and failure level of each component of the running equipment can be obtained.

Local maintenance personnel who install and operate equipment can connect to cloud servers through mobile terminals such as mobile phones, tablets, and laptops. From the Ankang cloud control platform, they can keep abreast of equipment operation or fault conditions in order to carry out targeted maintenance or maintenance, and can The earth improves work efficiency.

Although the present invention has been disclosed in the above preferred embodiments, the present invention is not limited to this. For example, the vibration temperature sensor of the present invention can be applied not only to the operation equipment (such as elevator car, elevator traction machine, machine pump, motor) that have been exemplified, but also to almost all types of Run the device and rotate the device. Any application or modification made by those skilled in the art without departing from the spirit and scope of the present invention shall fall within the protection scope of the present invention.

Claims

A vibration temperature sensor for the monitoring of the operating data of the operating equipment includes a housing for packaging; it is characterized in that a triaxial vibration sensing module, a temperature monitoring module, a filtering module, a data processing module are built in the housing The wireless communication module and the battery module, the three-axis vibration sensing module are sequentially connected to the filter module and the data processing module through the signal line, the temperature monitoring module and the wireless communication module are respectively connected to the data processing module through the signal line, and the battery module is used for each component powered by.
The vibration temperature sensor according to claim 1, wherein a switch module is provided on the housing, and the switch module is connected to the data processing module through a signal line.
The vibration temperature sensor according to claim 1, characterized in that a magnetic base module is provided at the bottom of the casing for fixed installation by magnetic attraction.
The vibration temperature sensor according to claim 1, wherein the battery module is a lithium battery with a charging interface.
The vibration temperature sensor according to claim 1, wherein the wireless communication module is a LoRa communication module, a Wi-Fi communication module, or an NB-IOT communication module.
The vibration temperature sensor according to any one of claims 1 to 5, wherein a calculation software module is embedded in the data processing module to convert the vibration acceleration data collected by the triaxial vibration sensing module into The effective value of the vibration velocity and the output of the Fourier transform are the three-axis vibration waveform diagram and spectrum diagram.