CN103913193A - Device fault pre-maintenance method based on industrial wireless technology - Google Patents
Device fault pre-maintenance method based on industrial wireless technology Download PDFInfo
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Abstract
The invention relates to a device fault pre-maintenance method based on an industrial wireless technology. In the method, through data communication of an industrial wireless network and an industrial Ethernet, real-time monitoring and fault pre-maintenance are performed on an on-site device. The method includes the following steps: an upper computer performs parameter configuration on on-site instruments, which are used for monitoring the device, through the industrial Ethernet and the industrial wireless network; the instruments acquire sensor information of the on-site device according to the parameter configuration and upload result data, which is obtained after local processing of the sensor information, to the upper computer through the industrial wireless network and the industrial Ethernet; the upper computer performs fault diagnosis according to the result data and judges the operation state of the device; and if the fault diagnosis result is obtained, on-site maintenance personnel are notified through a fault alarm so as to maintain the device.
Description
Technical field
The present invention relates to the pre-maintaining method of a kind of equipment failure based on Industrial Wireless, specifically a kind of pre-diagnostic method of wireless malfunction for rotating machinery (motor, blower fan, pump etc.) based on signals such as vibration, voltage, electric current, temperature.
Background technology
Along with the progress of technology, modern process industry to maximizing, integrated, robotization and high speed future development.Production run for equipment reliability of operation require more and more higher, need its under severe operating mode continuously, efficiently, for a long time operation.In process industry, the chance failure of key equipment can cause serious economic loss, and the catastrophic effect even causing casualties and rugged environment pollute.Therefore, building a kind of efficient, reliable plant equipment maintenance system is to reduce costs, and improves profit, strengthens the effective means of enterprise competitiveness.
Traditional plant maintenance mode adopts the maintenance policy such as " correction maintenance ", " periodic maintenance ", but the maintenance that this maintenance mode exists not in time, cross repair, owe to repair, overall maintenance cost crosses the problems such as high, " based on the maintenance of state " is a kind of impact under the prerequisite of production run, the technology such as comprehensive utilization sensor, detection, communication, computing machine and artificial intelligence, running status to key equipment is monitored in real time, can find out potential faults, location fault rootstock, prediction fault progression trend, provides the tactful complex art of fixing a breakdown.
At present, the maintenance based on state, because implementation cost is higher, has only obtained application in large-scale key core equipment.Also have the no-man's-land of a large amount of key equipments in monitoring for medium-sized and small enterprises, its daily servicing still adopts the mode of periodic maintenance, therefore provides a kind of fault diagnosis solution of the maintenance based on state cheaply to have important using value.In addition, Integrated Fault Diagnosis System in a large amount of built enterprises, not only cost, construction cost are high to lay cable, and system reconfigures difficulty, and reliability is low.And Industrial Wireless can well address these problems, Industrial Wireless has been eliminated the dead angle of traditional wired TT&C system, has widened time, the Spatial Dimension of TT&C system.
In the enterprises such as petrochemical industry, metallurgy and electric power, the equipment such as motor, blower fan, compressor, pump are all key equipments, need to monitor in real time its duty, realize the maintenance based on state.These equipment can produce some faults in operational process, such as the uneven or impact of rotor, rolling between part and phase mutual friction, the gap producing between part or loosening, what piece surface produced peels off or crackle etc., can cause the signals such as equipment voltage, electric current, temperature, vibration to occur abnormal, therefore, these signals be monitored and can effectively equipment state be monitored.
Summary of the invention
In order to overcome the deficiency of currently available technology, the invention provides the pre-maintaining method of a kind of equipment failure based on Industrial Wireless, the technical solution used in the present invention is:
The pre-maintaining method of equipment failure based on Industrial Wireless, by the data communication of industrial wireless network and Industrial Ethernet, carries out Real-Time Monitoring and Fault Pre maintenance to field apparatus; Comprise the following steps:
Host computer carries out parameter configuration to scene for the instrument of watch-dog by Industrial Ethernet and industrial wireless network; Instrument is according to the sensor information of this parameter configuration collection site equipment, and sensor information is carried out to local result data after treatment is uploaded to host computer by industrial wireless network, Industrial Ethernet;
Host computer carries out fault diagnosis according to result data, judgment device running status; If obtain fault type, notify field maintemance personnel to keep in repair equipment by fault alarm.
Described equipment comprises motor, blower fan, pump, compressor.
Described parameter configuration comprises sample frequency, refresh cycle, threshold value, instrumentation pattern, image data time, sensor passage number.
Described sensor information comprises voltage, electric current, temperature, vibration information.
In described local processing, vibration transducer information is carried out to this locality processing and comprises:
The vibration acceleration data of vibration transducer collection are obtained to vibration velocity data by an integral operation, obtain vibration severity according to vibration velocity data;
The vibration acceleration data of vibration transducer collection are carried out to Fast Fourier Transform (FFT), obtain the frequency spectrum of vibration acceleration, obtain the amplitude size of assigned frequency component according to frequency spectrum;
The vibration acceleration data of vibration transducer collection are compressed and obtained packed data.
Described result data comprises voltage, electric current, temperature data, vibration severity, the amplitude size of assigned frequency component, packed data.
Described host computer carries out fault diagnosis according to result data, judgment device running status comprises the following steps: result data is inputed to Fault Diagnosis Database, obtain the fault diagnosis result of fault type by the result data in Fault Diagnosis Database, device parameter, outcome history data, threshold value and fault type.
Described threshold value comprises the threshold value of the amplitude size of voltage, electric current, temperature data, vibration severity, assigned frequency component.
Described fault alarm can also be sent to field device maintenance personnel with the form of cellphone information by warning message and maintenance suggestion by local sound and light alarm or 3G network.
The present invention has following beneficial effect and advantage:
1. the present invention adopts Industrial Wireless as networking mode, has improved the dirigibility of networking, has strengthened system reliability, has eliminated the dead angle of traditional wired TT&C system, has widened time, the Spatial Dimension of TT&C system.
2. the present invention has realized the maintenance based on state to equipment such as motor, pump, blower fans, has improved the efficiency of plant maintenance, has reduced the expense of plant maintenance, has strengthened the reliability of equipment work.
3. the mode that adopts local sound and light alarm and 3G mobile network alarming to combine, makes plant maintenance personnel can grasp anywhere or anytime the work at present situation of equipment, has ensured the promptness of maintenance of equipment.
Brief description of the drawings
Fig. 1 Fault Pre maintenance system overall construction drawing based on Industrial Wireless of the present invention;
Fig. 2 industrial wireless communication schematic diagram of the present invention;
Fig. 3 field monitoring subsystem structure figure;
Fig. 4 wireless transmitter workflow diagram;
Fig. 5 fault diagnosis center diagnostic flow chart.
Embodiment
Below in conjunction with embodiment, the present invention is described in further detail.
The state of field instrument Real-Time Monitoring controlled device, gather different data messages, data processing and preliminary fault diagnosis are carried out in this locality, then the data after compression are reached to level of factory Surveillance center by wireless network and realize fault diagnosis, the fault of local monitor center None-identified can on give remote failure Surveillance center, held a consultation by expert.Fail result shows by various ways such as local instrument, Surveillance center, and supports the result transmission of 3G network smart mobile phone.
The pre-maintenance system of a kind of equipment failure based on Industrial Wireless, comprise the composition structure of system, the working method of wireless instrument, the constituted mode of wireless network, realize level of factory malfunction monitoring center and the remote fault diagnosis expert service center of fault diagnosis, support fault diagnosis result by 3G network with multimedia mode announcement apparatus maintainers such as word, chart, audio frequency, videos.Fault diagnosis and equipment that whole Fault Pre maintenance system can be used for the rotating machineries such as motor, blower fan, pump are safeguarded in advance.
The invention provides the pre-maintenance solution of a kind of equipment failure based on wireless industrial, wireless instrument Real-time Collection monitored target (motor, blower fan, the rotating machineries such as pump) voltage, electric current, temperature, the signals such as vibration, the signal collecting is carried out to pre-service and primary signal analysis in this locality, passing threshold judgement realizes primary fault analysis and warning, then by wireless self-networking by compression after time domain, frequency-region signal is delivered to level of factory Surveillance center and is realized fault high level diagnostics, the running status of judgment device, Judging fault classification and degree, provide maintenance suggestion, realize pre-maintenance.The fault that cannot diagnose at level of factory diagnostic center, sends into remote fault diagnosis expert service center by internet, is held a consultation by domain expert, then diagnostic result is turned back to level of factory fault diagnosis center.Fault diagnosis result can show at different stages such as local instrument, level of factory Surveillance center, remote diagnostic centers.Support the information such as fault alarm to be sent on plant maintenance personnel's smart mobile phone by 3G network, realize the full-time empty monitoring of equipment.
Fig. 1 is the Fault Pre maintenance system general system set-up figure based on Industrial Wireless, and native system is made up of field instrument system 60, wireless industrial data transmission network 40, Industrial Ethernet 30 and fault diagnosis and fault alarm reporting system.Can have multiple according to concrete monitoring demand field monitoring subsystem 60, such as the system configuration that industry spot can be distributed in to different workshops becomes monitoring subsystem separately, the kind of the wireless instrument adopting in each subsystem, quantity are specifically determined according to the character of monitoring target.Data from on-site wireless instrument are connected in wireless data transmission network 40 by wireless communication signals 50, are transferred data in Industrial Ethernet by the wireless industrial gateway 41 in 40.The signals such as vibration, voltage, electric current and the temperature of level of factory fault diagnosis center 12 to the monitored target from industry spot carry out data processing, the work at present state of analytical equipment, determine whether equipment breaks down, if break down, locate trouble location, determine fault type, and provide rational maintenance of equipment suggestion.Be subject to the restriction of current artificial intelligence technology development, can solve all troubleshooting issues without any fault diagnosis expert system, if level of factory fault diagnosis center 12 has difficulties in failure diagnostic process, remote fault diagnosis expert service center 13 will be delivered to by internet 20 on diagnostic task, request domain expert's assistance.If domain expert returns to level of factory fault diagnosis center 12. level of factory fault diagnosis centers 12 by internet 20 again by diagnostic result and finds fault, by fault alarm reporting system 14, the information such as warning message, abort situation, fault type, suggestion treatment measures are sent to the maintenance of equipment personnel that are responsible for equipment safety operation.In view of the development of current 3G mobile communication technology and development of Mobile Internet technology, fault alarm reporting system is supported Transmitting of Multi-media Information; Such as passing through the form announcement apparatus maintenance personal of SMS.Wireless network server 11 completes the configure and maintenance to on-the-spot wireless industrial instrument and wireless industrial data transmission network 40.The wireless instrument that can realize being distributed in industry spot by wireless network server 11 is realized the operations such as start and stop, parameter configuration, Breakdown Maintenance.
Parameter configuration comprises sample frequency, refresh cycle, threshold value, instrumentation pattern, image data time, sensor passage number; Threshold value involving vibrations earthquake intensity threshold value, vibration acceleration frequency spectrum assigned frequency component amplitude threshold value, temperature threshold, voltage threshold and current threshold; Instrumentation pattern comprises normal mode of operation and energy-saving mode.
Fig. 2 is industrial wireless communication schematic diagram of the present invention.Wireless network is made up of wireless industrial gateway 41, wireless router 42 and wireless instrument 43.The concrete wireless communication technology of selecting can be WIA(WirelessNetworks for Industrial Automation), the mode such as Wireless HART, ISA100.The type of wireless instrument 43 can be wireless vibration transmitter, wireless current transducer, radio pressure transmitter, wireless temperature transmitter etc., and particular type is determined according to diagnosis object.The communication mode of wireless instrument 43 and radio network gateway 41 is definite according to distance between the two, if in the distance that distance is between the two jumped at wireless instrument 43 1, and wireless instrument 43 and radio network gateway 41 direct communications; If distance is between the two greater than the distance of a jumping, between wireless instrument 43 and radio network gateway 41, suitable position installation wireless router 42 carries out relaying to data.Wireless network 40 is a kind of self-organization mesh networks, automatically the adding, exit of support equipment.Therefore, network has configuration easily, and reliability is high.
Fig. 3 is field monitoring subsystem structure figure.System is made up of detected object 69, sensor 62,64,66,68, wireless transmitter 61,63,65,67, sensor converts the physical signalling that contributes to fault diagnosis to electric signal, such as, signal can be voltage, electric current, temperature, vibration signal, certainly be not limited to these signals, also can be other signals such as sound, image, particular type will be determined according to the nature of trouble of the type of monitoring target and plan diagnosis.For example, if monitoring target 69 is a unit being made up of motor-water pump, it is carried out to malfunction monitoring is to utilize voltage sensor 64, current sensor 66 to monitor respectively the voltage and current of motor in measurand 69, and the signal that sensor is detected send radio pressure transmitter 63, wireless current transducer 65 to process; Utilize temperature sensor 62 to monitor the bearing bush temperature of unit load end motor, send wireless temperature transmitter 61 to process signal; Utilize X, the Y of multiple vibration transducers 68 to the multiple measuring points of unit, the vibration signal of Z-direction to detect, result is delivered to the wireless vibration transmitter 67 of multiple correspondences and processed.It can be that threshold decision, time-domain signal compression, frequency-region signal Fast Fourier Transform (FFT) (FFT) are analyzed etc. that each wireless transmitter data after treatment send into by wireless signal signal processing that industry wireless communication network 40 carries out in wireless vibration transmitter.
Threshold decision is specially: if formulating the amplitude of frequency component, the size of temperature, voltage, current signal and vibration signal be greater than the threshold value that host computer is formulated, and local warning, and warning message is uploaded to host computer;
Time-domain signal compression is specially: adopt wavelet transformation to compress the vibration acceleration signal time domain data that need to be transferred to host computer, reduce the byte number that need to transmit by industry wireless network, adopt corresponding decompression algorithm at host computer, reduction time domain vibration acceleration data.
Vibration acceleration signal Fast Fourier Transform (FFT) (FFT) is analyzed and is specially: the vibration acceleration signal gathering is carried out to FFT conversion, obtain the frequency spectrum of vibration acceleration signal, the fundamental frequency of the equipment operation of setting according to host computer, calculates the size of assigned frequency component (such as 0.5 frequency multiplication, 1 frequency multiplication, 2 frequencys multiplication, 3 frequencys multiplication, 4 frequencys multiplication, 5 frequencys multiplication etc.) amplitude.
Fig. 4 is wireless transmitter workflow diagram.Wireless vibration transmitter is generally powered battery, in order to reduce power consumption, improve the serviceable life of battery, on transmitter, be provided with power management function, transmitter, according to the refresh cycle of setting, starts the works for the treatment of such as transmitter data acquisition, analysis, data transmission.In initialization 72, load start-up routine, be written into configuration parameter, the instruction of identification current operation.Wireless transmitter starts 71 work the each module of wireless transmitter hardware is powered on, and after initialization 72 completes, enters data acquisition 73, and data acquisition comprises the operations such as A/D conversion, digital filtering, data scaling; Data scaling is to obtain vibration signal size according to the digital quantity after analog to digital converter ADC conversion and the voltage resolution of ADC and the resolution of vibration transducer.Then enter next step and 74 carry out data processing and local threshold decision stage, data processing comprises time-domain signal analysis and frequancy signal anaysis, data compression process, reduce wireless network data transmission quantity, improve battery, simple threshold value comparison is carried out in instrument this locality, comprises voltage, electric current, temperature, vibration threshold, carry out this locality if transfinite and report to the police 75, by the mode announcement apparatus maintainer of alarm sound.Then wireless vibration transmitter starts radio receiving transmitting module, start connecting wireless network 76, network connects complete log-on data transmission 77, transmission voltage, electric current, temperature time domain data, vibration acceleration signal time domain data after analysis of vibration signal result data and compression, wireless transmitter finishes a work period 78, waits for the beginning of next work period; Carry out senior Analysis on Fault Diagnosis at level of factory fault diagnosis center and remote fault diagnosis center.Wherein: analysis of vibration signal data are the amplitude size of specifying frequency component in vibration severity and vibration acceleration signal frequency spectrum.Assigned frequency is the frequency that host computer is set according to the fault type of the rotating speed of monitored target and plan diagnosis.
Fig. 5 is fault diagnosis center process flow diagram.Enter after failure diagnostic process 81, first data from on-the-spot vibration transmitters enter level of factory fault diagnosis 82, if the difficult and complicated cases that cannot process at level of factory fault diagnosis center are sent into long-range fault diagnosis expert service center by internet, in remote fault diagnosis 83, show and hold a consultation according to fault by domain expert, and diagnostic result is returned to level of factory fault diagnosis center, if find that there is fault or potential fault enters fault alarm 84 and announcement apparatus maintainer 85 notifies relevant plant maintenance personnel after diagnosis; Finish this fault diagnosis 86.
Level of factory fault diagnosis center is specially the diagnostic data base that contains result data, device parameter, outcome history data, threshold value and fault type; Result data is inputed to Fault Diagnosis Database, obtain fault diagnosis result by the result data in Fault Diagnosis Database, device parameter, outcome history data, threshold value and fault type.Threshold value comprises the threshold value of formulating frequency component in voltage, electric current, temperature, vibration severity, vibration acceleration frequency spectrum.In diagnostic data base, also there is the maintenance information that diagnostic result is corresponding, for assisting maintenance of equipment personnel to realize plant maintenance, sends to plant maintenance personnel with warning message.
The diagnosis of diagnostic data base realizes by equipment running status and experience, for example: if there is the higher hamonic waves such as 2 frequencys multiplication, 3 frequencys multiplication in the frequency spectrum of vibration signal, vibrate unstable; Direction of vibration is for radially, axially, and fault type is that transversal crack appears in machine shaft; If 0.5 frequency multiplication appears in the frequency spectrum of vibration signal, vibration is stable, and direction of vibration is that axially fault type is oil whirl; If 2 frequencys multiplication appear in the frequency spectrum of vibration signal, frequency separation amplitude increases with the increase of rotating speed, and fault type is for misaligning.
Claims (9)
1. the pre-maintaining method of the equipment failure based on Industrial Wireless, is characterized in that, by the data communication of industrial wireless network and Industrial Ethernet, field apparatus is carried out to Real-Time Monitoring and Fault Pre maintenance; Comprise the following steps:
Host computer carries out parameter configuration to scene for the instrument of watch-dog by Industrial Ethernet and industrial wireless network; Instrument is according to the sensor information of this parameter configuration collection site equipment, and sensor information is carried out to local result data after treatment is uploaded to host computer by industrial wireless network, Industrial Ethernet;
Host computer carries out fault diagnosis according to result data, judgment device running status; If obtain fault type, notify field maintemance personnel to keep in repair equipment by fault alarm.
2. the pre-maintaining method of a kind of equipment failure based on Industrial Wireless according to claim 1, is characterized in that: described equipment comprises motor, blower fan, pump, compressor.
3. the pre-maintaining method of a kind of equipment failure based on Industrial Wireless according to claim 1, is characterized in that: described parameter configuration comprises sample frequency, refresh cycle, threshold value, instrumentation pattern, image data time, sensor passage number.
4. the pre-maintaining method of a kind of equipment failure based on Industrial Wireless according to claim 1, is characterized in that: described sensor information comprises voltage, electric current, temperature, vibration information.
5. the pre-maintaining method of a kind of equipment failure based on Industrial Wireless according to claim 1, is characterized in that: in described local processing, vibration transducer information is carried out to this locality processing and comprise:
The vibration acceleration data of vibration transducer collection are obtained to vibration velocity data by an integral operation, obtain vibration severity according to vibration velocity data;
The vibration acceleration data of vibration transducer collection are carried out to Fast Fourier Transform (FFT), obtain the frequency spectrum of vibration acceleration, obtain the amplitude size of assigned frequency component according to frequency spectrum;
The vibration acceleration data of vibration transducer collection are compressed and obtained packed data.
6. the pre-maintaining method of a kind of equipment failure based on Industrial Wireless according to claim 1, is characterized in that: described result data comprises voltage, electric current, temperature data, vibration severity, the amplitude size of assigned frequency component, packed data.
7. the pre-maintaining method of a kind of equipment failure based on Industrial Wireless according to claim 1, it is characterized in that: described host computer carries out fault diagnosis according to result data, judgment device running status comprises the following steps: result data is inputed to Fault Diagnosis Database, obtain the fault diagnosis result of fault type by the result data in Fault Diagnosis Database, device parameter, outcome history data, threshold value and fault type.
8. the pre-maintaining method of a kind of equipment failure based on Industrial Wireless according to claim 7, is characterized in that: described threshold value comprises the threshold value of the amplitude size of voltage, electric current, temperature data, vibration severity, assigned frequency component.
9. the pre-maintaining method of a kind of equipment failure based on Industrial Wireless according to claim 1, is characterized in that: described fault alarm can also be sent to field device maintenance personnel with the form of cellphone information by warning message and maintenance suggestion by local sound and light alarm or 3G network.
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