CN101893510A - Device-based one-machine-one-file on-line monitoring and fault diagnosis system - Google Patents
Device-based one-machine-one-file on-line monitoring and fault diagnosis system Download PDFInfo
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- CN101893510A CN101893510A CN2009100278815A CN200910027881A CN101893510A CN 101893510 A CN101893510 A CN 101893510A CN 2009100278815 A CN2009100278815 A CN 2009100278815A CN 200910027881 A CN200910027881 A CN 200910027881A CN 101893510 A CN101893510 A CN 101893510A
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Abstract
The invention belongs to the technical field of automated management of devices and particularly relates to a device-based one-machine-one-file on-line monitoring and fault diagnosis system. The system mainly comprises the following devices: 1) an intelligent vibration data collector used for collecting the vibration, phase, gap voltage and revolution speed of a machine unit; 2) a server used for managing the vibration data collector, a process data collector, network users, a historical database, a dynamic Web database and the like; 3) a diagnosis station microcomputer specially used to perform analysis and diagnosis for the professional and an output device; 4) optional workshops, branch plants and field monitoring stations; 5) optional authorized online work stations used for browsing the information of the machine unit; 6) network equipment; 7) application softwares used for analysis, diagnosis, setting and configuration; and 8) various optional portable instruments. The system can be used to change the device management form the manual management mode to the computer processing mode, thus conveniently solving the problems of large data, difficult inquiry and the like, saving time, reducing cost and having remarkable economic benefit.
Description
Technical field: the invention belongs to equipment automatization administrative skill field, be specifically related to the large-scale unit of large and medium-sized enterprise
The technological means of controlled management, particularly based on an one-machine-one-file on-line monitoring and the fault diagnosis system of equipment.
Background technology: for flow process enterprises such as oil, chemical industry, electric power, metallurgy, because its large-scale crucial unit is in vital position aborning, huge to enterprise's productivity effect influence, therefore this kind equipment is implemented monitoring running state and diagnoses just to seem particularly important that the requirement of monitoring, diagnosing is also higher than general device simultaneously.The first, monitoring parameter also should comprise relevant technology amount and switching value except that vibratory output, is convenient to comprehensive, accurately analysis; Data acquisition modes wants flexibly, convenient, as possess the constant duration sampling, etc. the phase angle sampling, etc. multiple different data acquisition modes such as rotating speed interval sampling, threshold value sampling, to adapt to on-the-spot different requirement; Avoid the unit failure message to lose simultaneously, the key equipment in producing adopts continuous on-line monitoring mode as far as possible as far as possible.The second, should be equipped with multiple signal analysis method, so that, improve analyzing and diagnosing ability to exceptional fault from a plurality of sides and angle analysis-by-synthesis unit operation situation.The 3rd, should have stronger data base administration and analysis ability, be beneficial to crash analysis, state forecast and improve the equipment control level.The 4th, also should have stronger network function, be convenient to the multidate information that equipment management personnel is understood unit operation whenever and wherever possible on the one hand, on the other hand, when exceptional fault appears in unit, be convenient to realize networked remote expert consultation, the purpose of reach fast, accurately diagnosing.The the 5th: must combine with the Whole Course Management data system of equipment, be convenient to control business equipment ruuning situation and failure condition comprehensively.The the 6th: must realize state maintenance with the accurate combination of management.
Big unit monitoring diagnosis system has multiple version.Diagnostic system the earliest is to be made of a microcomputer, and monitoring, diagnostic function are born by the separate unit microcomputer, and function is not really desirable.Occurred upper and lower machine system subsequently, by the slave computer monitoring, the requirement of diagnostic techniques has been satisfied in the host computer analysis basically, and weak point is that slave computer takes the timesharing routine inspection mode that machine group is monitored, and failure message has the possibility of losing.Along with technical progress, development of internet technology particularly, the networking distributed monitoring system arises at the historic moment, adopt the mode of distributed collection, collective analysis management, add the application of volume server, can improve the function of diagnostic system greatly, reach the requirement of on-line monitoring, diagnosis, forecast and information sharing.
Equipment condition monitoring and breakdown diagnosis technology and Equipment Management in Enterprise system and procedures control system equal altitudes are combined together, and realization information links up and fully shares, and is an urgent demand of business administration work.On hardware, the monitoring diagnosis system data acquisition unit must be realized connecting with the Intranet/Internet net of enterprise and the relevant devices of field process control system (as: PLC, DCS, field bus instrument) on Physical layer; Aspect data sharing, must realize seamless exchanges data with the management application software (as: MIS, ERP) and the on-the-spot measuring and controlling equipment (as: PLC, in-line meter) thereof of enterprise, and support the emerging technology of Web technology and Embedded Application etc.; Aspect software,, should be equipped with more more advanced failure analysis methods for further improving accuracy of fault diagnosis.
Summary of the invention: the objective of the invention is at above-mentioned the deficiencies in the prior art, design and develop online image data (involving vibrations, rotating speed, technology amount) in a kind of long-range or net, refreshed storage once in 2 seconds, and in real time an one-machine-one-file on-line monitoring and the fault diagnosis system based on equipment of monitoring and diagnosis fault.
Management system module of the present invention is mainly used networked high speed on-line monitoring system (mainly big unit being realized the network real-time on-line monitoring), interrelated with equipment management system, assists mutually and deposits mutually, and shared data improves the equipment fault diagnosis accuracy rate.Particularly utilize the on-line data acquisition technology, data acquisition unit and data processing centre (DPC) carry out communication, with the simulated data digital conversion of gathering, carry out various algorithms, show time domain, frequency domain, orbit of shaft center etc.Employing equipment " one grade in a machine " mode, recording unit overall process cycle life-cycle archives, comprise detailed archives, logout, the maintenance record, drawing, the quota spare part, nonstandard spare part, data (the involving vibrations of online acquisition, rotating speed, the technology amount,) 2 seconds refresh storage once, accurately and timely, comprehensive collection is got up, for the multianalysis equipment running status provides full and accurate data, analyzing and diagnosing through intelligence, notify the related management personnel in modes such as mobile phone short messages, the equipment health status is sent diagnosis report automatically, can realize long-range expert diagnosis,, realize all large-scale unit controlled management of enterprise for maintenance provides decision-making.
The present invention is achieved like this: system mainly comprises following a few part:
1) is used to gather the intelligent vibration data acquisition unit of unit vibration, phase place, gap voltage, rotating speed; 2) be used to manage the server of vibrating data collection device, process data collector, the network user, historical data base, Dynamic Web database etc.; 3) be exclusively used in diagnostic terminal microcomputer and the output device that the professional analyzes and diagnoses; 4) optional workshop, subsidiary factory, field monitoring station; What 5) optionally be used to browse unit information has workstation through permission on the net; 6) network equipment (shared with Intranet) as Switch, HUB, Roter etc.; 7) be used for application software such as analysis, diagnosis, setting and configuration; 8) optional various portable instrument.
System of the present invention can be long-range, online monitoring and fault diagnosis in also can netting.
General intelligent vibration data acquisition unit of the present invention adopts asic technology, and pre-process circuit is designed to independently ASIC integrated circuit of a slice, each passage a slice.
System of the present invention has following characteristics:
1) on the network in general structure, can combine together with existing intranet of enterprise (Intranet) and Internet net height degree, the equipment on-line monitoring grid before having broken is with the separate structure of enterprise internal management network.Widely with low cost, merge by the height with Intranet and Internet on the other hand on the one hand, information can be shared on a large scale, the situation that the status monitoring information before of having changed can only be shared among a small circle.
2) for improving to the vibration signal pretreatment precision, adopt special-purpose ASIC (special IC) to design the pre-process circuit of signals such as vibration, phase demodulation, to realize that signal high speed, parallel, high precision pre-service have been changed the modular design mode of traditional general purpose I C and resolution element.
3) for realize to multi channel signals (16 passage) walk abreast, synchronous, integer-period sampled, utilize ASIC, FPGA, high-speed a/d converter to design high speed signal, the parallel synchronous sample circuit of a cover.This circuit can carry out the parallel synchronous sampling to multiple signals, has reduced the use amount of A/D and the complicacy and the cost of sampling plate again.
4) be to catch the unit alert data fast, used the pre-Sampling techniques of reporting to the police, set up in case report to the police, pre-sampling buffer data will be freezed at once, the sampling response speed of having accelerated to report to the police.
5) for catching any abnormal vibrations value fluctuation (as unexpected minimizing or increase) in the alarming value, use increment sampling and increment rate of change or further feature quantitative changeization (as 1X, 2X etc.) to trigger Sampling techniques, any abnormal vibrations data can be caught by the assurance system.
6) for repeatedly sampling out automatically/the docking process data, utilize the ASIC circuit engineering to adopt machine to open/the automatic sample circuit of docking process.Utilize this circuit, the fluctuation of speed value that collector can set according to the user, automatically judge whether machine enters out/docking process or routine operation process, so that adopt corresponding sampling pattern, whole process need not any manual intervention, open/the parking data storehouse can be preserved and be opened for 1000 times/the docking process data.
7) for realizing that high-speed electric expreess locomotive is dragged unit to be left/the docking process sampling, adopted special high speed to open/the parking sample circuit, its opening/parking data of 16 passages of can in 8～15 seconds, sampling simultaneously.
8) open for more accurately judging/critical rotary speed of docking process, adopted to open/docking process data sampling encryption technology, be whole opening/docking process (comprising motor) sampling 320 quiescent values (P-P, Rot, 1XA, 1XP etc.) and 32 groups of dynamic waveforms, per 10 groups of static point one group of dynamic waveform of sampling.
9) for reducing the maintenance workload of system hardware and software, adopted remote maintenance system, utilized Internet and Intranet can realize remotely modifying and maintenance the collector operational factor.
10) use for the convenience of the user, used C/S+B/S dual structure software.The C/S infrastructure software is suitable for the professional technician and uses and system is carried out rigorous analysis, parameter setting and configuration etc.The B/S infrastructure software then is applicable to public users, and the user only need utilize browser to consult the related content of sending in the Dynamic Web homepage, and easy to use, maintenance workload is little etc.
11) for accurately and efficiently preserving dynamic original waveform, triple triggering preservation technology and corresponding data compression technique have been adopted.The one, regularly trigger, the 2nd, Event triggered (as warning, data exception fluctuation etc.), the 3rd, manual control triggers.These three kinds of mode commons replenish mutually, guarantee the complete dynamic data of preserving efficiently.
12) for adapting to the application of large-scale Intranet and Internet, in data acquisition unit, used functional software such as the empty net of automatic support, subnet division and webmaster, be convenient to the network unified management, and collector there is the automatic recovery capability of network.
13) be accurately to analyze chain jumping car order, adopted sampling of speed-sensitive switch amount and analytic system.Can realize switch amount high-speed sampling (resolution 0.5ms), its software can be analyzed interlocking and jump the car time sequencing.
14) be accurately comprehensively to describe the machine state feature, provide 30 surplus kind of a characteristic parameter deposit historical data base in, and allow the user to define a plurality of characteristic variables voluntarily to preserve.
15) for preserving the feature historical data efficiently, for a long time, adopted efficient fast data compression and memory technology, make the user can consult the characteristic in 12 hours～10 years at any time.
16) be to describe machine state, contents such as its feature historical data base support vibration, technology, iron spectrum data, oil analysis data, infrared thermal-image data and field condition description are comprehensive, large databases, and support data warehouse applications comprehensively.
17) be as the criterion and make a definite diagnosis disconnected fault, except that conventional analysis, used orbit of shaft center decompose with synthetic, wavelet analysis, Winger distribute, analytical approachs such as spectrum comparison, track trend, help improving the accuracy of diagnostic result.
18) comprehensive compatible off-line data collector data, accurate online monitoring data, and have the Data Format Transform ability.
19) for ease of the output analysis report, analysis result supports and desktop system integrated (as Word, excel) that comprehensively the while data can import ERP and use.
20) software has powerful setting and configuration function, and many documents Presentation Function makes things convenient for advantages such as the onsite user uses.
Description of drawings: accompanying drawing 1 is an embodiment of the invention system architecture synoptic diagram.
Embodiment: the present invention is described in detail below in conjunction with accompanying drawing 1 and embodiment.
Embodiment: as shown in Figure 1, (1) makes full use of intranet (Intranet) and Internet resource, highly combines together with Intranet and Internet, realizes resource sharing, reduces investment outlay.The MD3905 1Aplus system of present embodiment is by data acquisition unit (involving vibrations and technology amount), database server, analyzing and diagnosing microcomputer, output device and several browsers are formed as a result, highly be fused into one with the Intranet of enterprise, make full use of the Intranet of enterprise resource, reduce cost of investment, can give full play to the usefulness of the Intranet of enterprise again.It is convenient to the network by Internet again on the other hand, realizes remote diagnosis.
MD39051 Aplus has alert data is sent to ability in the Email automatically.In a single day system detects the unit of being monitored has warning and anomalous event to take place, its data will be automatically send among the mailbox of diagnostic center or other diagnostician's the mailbox by Email, and by notifying from a phone call or SMS (short message service) is in time notified each analyzing and diagnosing expert with above-mentioned e-mail messages, for the user provides diagnostic result fast.
(2) network hardware structural support subnet and empty net are divided
The B/S+C/S tactic pattern is adopted in network application.Each collector of MD3905 1Aplus network system adopts ICP/IP protocol, supports subnet and empty net to divide, and is convenient to form the network of various scales.On application mode, for the employing R/S of the unit structure of administrative authority's one-level, promptly browser/server structure uses IE just can consult the various status datas of sending in the dynamic WEB homepage, and the professional then adopts the C/S structure, is convenient to carry out profound level analysis.
Effect after the embodiment of the invention is implemented:
1. make equipment control carry out the transition to computer processing mode, solved problems such as data volume is big, inquiry difficulty easily, the reduction expense saves time from manual management mode.
2. alleviate labour intensity, improved the work efficiency in the daily management.
3. improved the quality of analytic statistics, avoided the various errors in the manual statistics, and can make relevant department in time obtain information needed.Can rationally formulate turnaround plan, reduce unnecessary maintenance spending.
4. enlarge management function and range of management, improved management level, obtained tangible economic benefit.
5, reduce unplanned parking, reduce Parts Inventory, predict and trouble location and failure cause reduce a large amount of checking maintenance expenses in advance.
Claims (8)
1. an one-machine-one-file on-line monitoring and fault diagnosis system based on an equipment is characterized in that system mainly comprises following a few part:
1) is used to gather the intelligent vibration data acquisition unit of unit vibration, phase place, gap voltage, rotating speed; 2) be used to manage the server of vibrating data collection device, process data collector, the network user, historical data base, Dynamic Web database; 3) diagnostic terminal microcomputer and the output device of analyzing and diagnosing; 4) network equipment; 5) be used to analyze, diagnose, the application software of setting and configuration.
2. the system as claimed in claim 1 is characterized in that it also comprises workshop, subsidiary factory, field monitoring station.
3. the system as claimed in claim 1, it is characterized in that it also comprise be used to browse unit information workstation through permission arranged on the net.
4. the system as claimed in claim 1 is characterized in that it also comprises various portable instruments.
5. the system as claimed in claim 1 is characterized in that the intelligent vibration data acquisition unit adopts asic technology, is designed to independently ASIC integrated circuit of a slice, each passage a slice with pre-process circuit.
6. the system as claimed in claim 1 is characterized in that the network equipment is that Switch, HUB, Roter and Intranet are shared.
7. the system as claimed in claim 1 is characterized in that remote monitoring and fault diagnosis.
8. the system as claimed in claim 1 is characterized in that netting interior monitoring and fault diagnosis.
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| CN2009100278815A CN101893510A (en) | 2009-05-18 | 2009-05-18 | Device-based one-machine-one-file on-line monitoring and fault diagnosis system |
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| CN2009100278815A CN101893510A (en) | 2009-05-18 | 2009-05-18 | Device-based one-machine-one-file on-line monitoring and fault diagnosis system |
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Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102081808A (en) * | 2010-11-29 | 2011-06-01 | 辽宁工业大学 | Field apparatus inspection method and system |
| CN102123043A (en) * | 2011-01-05 | 2011-07-13 | 中国南方电网有限责任公司超高压输电公司百色局 | System capable of realizing secondary safety protection and supervision of substation |
| CN102915028A (en) * | 2012-02-16 | 2013-02-06 | 上海西门子工业自动化有限公司 | Diagnostic system and diagnostic method of PCS7 (process control system) software system |
| CN103020760A (en) * | 2012-12-05 | 2013-04-03 | 广州市正泰商业数据有限公司 | Comprehensive management platform of digitizing field |
| CN103605355A (en) * | 2013-12-10 | 2014-02-26 | 贵州电力试验研究院 | Method and system for rapidly and remotely monitoring vibration parameters of steam turbine generator unit in online |
| CN103760858A (en) * | 2014-01-15 | 2014-04-30 | 四川久大制盐有限责任公司 | Vacuum salt production DCS |
| CN104573307A (en) * | 2014-10-14 | 2015-04-29 | 山东创德软件技术有限公司 | Power station condition online diagnosis and operation optimization system based on data coordination |
| CN106698197A (en) * | 2016-12-01 | 2017-05-24 | 上海振华重工电气有限公司 | System for online diagnosis and preventive maintenance of container crane based on big data |
| CN104406785B (en) * | 2014-12-05 | 2017-06-06 | 北京合锐清合电气有限公司 | A kind of on-Line Monitor Device applied on intelligent ring main unit |
| CN108151795A (en) * | 2016-12-02 | 2018-06-12 | Abb瑞士股份有限公司 | For the method and system of configuration status monitoring device |
| CN111857082A (en) * | 2020-08-14 | 2020-10-30 | 昆山同日工业自动化有限公司 | Intelligent workshop remote diagnosis control system based on 5G network |
| CN114417741A (en) * | 2022-03-31 | 2022-04-29 | 北京恒信启华信息技术股份有限公司 | One-machine one-file equipment data management and processing system |
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2009
- 2009-05-18 CN CN2009100278815A patent/CN101893510A/en active Pending
Cited By (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102081808A (en) * | 2010-11-29 | 2011-06-01 | 辽宁工业大学 | Field apparatus inspection method and system |
| CN102123043A (en) * | 2011-01-05 | 2011-07-13 | 中国南方电网有限责任公司超高压输电公司百色局 | System capable of realizing secondary safety protection and supervision of substation |
| CN102915028B (en) * | 2012-02-16 | 2015-11-25 | 西门子工厂自动化工程有限公司 | The diagnostic system of PCS7 software systems and diagnostic method |
| CN102915028A (en) * | 2012-02-16 | 2013-02-06 | 上海西门子工业自动化有限公司 | Diagnostic system and diagnostic method of PCS7 (process control system) software system |
| CN103020760A (en) * | 2012-12-05 | 2013-04-03 | 广州市正泰商业数据有限公司 | Comprehensive management platform of digitizing field |
| CN103605355A (en) * | 2013-12-10 | 2014-02-26 | 贵州电力试验研究院 | Method and system for rapidly and remotely monitoring vibration parameters of steam turbine generator unit in online |
| CN103760858B (en) * | 2014-01-15 | 2016-07-06 | 四川久大制盐有限责任公司 | A kind of vacuum salt production DCS |
| CN103760858A (en) * | 2014-01-15 | 2014-04-30 | 四川久大制盐有限责任公司 | Vacuum salt production DCS |
| CN104573307A (en) * | 2014-10-14 | 2015-04-29 | 山东创德软件技术有限公司 | Power station condition online diagnosis and operation optimization system based on data coordination |
| CN104573307B (en) * | 2014-10-14 | 2018-02-13 | 山东创德软件技术有限公司 | A kind of power station state inline diagnosis and operation optimizing system based on data harmonization |
| CN104406785B (en) * | 2014-12-05 | 2017-06-06 | 北京合锐清合电气有限公司 | A kind of on-Line Monitor Device applied on intelligent ring main unit |
| CN106698197A (en) * | 2016-12-01 | 2017-05-24 | 上海振华重工电气有限公司 | System for online diagnosis and preventive maintenance of container crane based on big data |
| CN108151795A (en) * | 2016-12-02 | 2018-06-12 | Abb瑞士股份有限公司 | For the method and system of configuration status monitoring device |
| CN108151795B (en) * | 2016-12-02 | 2021-02-26 | Abb瑞士股份有限公司 | Method and system for configuring a condition monitoring device |
| CN111857082A (en) * | 2020-08-14 | 2020-10-30 | 昆山同日工业自动化有限公司 | Intelligent workshop remote diagnosis control system based on 5G network |
| CN114417741A (en) * | 2022-03-31 | 2022-04-29 | 北京恒信启华信息技术股份有限公司 | One-machine one-file equipment data management and processing system |
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Open date: 20101124 |