CN102662081A - A wireless acceleration sensor for vibration monitoring - Google Patents
A wireless acceleration sensor for vibration monitoring Download PDFInfo
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- CN102662081A CN102662081A CN201210090437XA CN201210090437A CN102662081A CN 102662081 A CN102662081 A CN 102662081A CN 201210090437X A CN201210090437X A CN 201210090437XA CN 201210090437 A CN201210090437 A CN 201210090437A CN 102662081 A CN102662081 A CN 102662081A
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Abstract
The invention relates to a wireless acceleration sensor for vibration monitoring. The wireless acceleration sensor, which includes two parts: hardware and software, is characterized in that: the hardware comprises a control circuit board, a sensor housing, a piezoelectric acceleration sensor, a strength magnetic seat, a lithium battery set and an antenna; and the software programming employs a layered design and the software is divided into a network layer, a media access control layer and a physical layer. According to the above-mentioned design scheme in the invention, the sensor has characteristics of lightweight structure and convenient assembling; and it is easy to realize mass production and large-scale layout. And utilization of the software system design enables power consumption of the sensor to be substantially reduced and service life of the sensor to be improved.
Description
[technical field]
The present invention relates to sensor technical field, specifically, is a kind of Wireless Acceleration Sensor that is used for vibration monitoring.
[background technology]
On current increasingly competitive market, enterprise faces improves process procedure efficient, and it is severe day by day with the challenge of satisfying self economic interests to observe environmental regulation.Consider that many industrial systems are aging day by day, and the dynamic change of industrial market, need efficient and yield-power that intellectuality, low-cost industrial automated system improve these systems badly.The Traditional industrial automated system relies on cable to connect and realizes.Yet wired automated system need be installed expensive communication line, and needs periodic maintenance.Thereby wired automated system is not widely used in industry.So, pressing for a kind of wireless automated systems cheaply, it can pass through to optimize the management of factory system, and then reaches the purpose of remarkable reduction spending and minimizing air pollutant emission.
Along with the progress on the present stage wireless sensor technology, the realization of low-cost Embedded wireless industrial automated system has become possibility.In these systems, small wireless senser is installed on the commercial unit, in conjunction with to such as the isoparametric comprehensive detection of vibration, temperature, pressure and power quality, monitors for all vital parameter of the efficient of every equipment.Afterwards, these parameters will be sent to Centroid through wireless mode, so that analyze the data of each sensor.It all notifies Plant personnel as a kind of early warning system with any potential problem.This just allows the related personnel to reduce or thoroughly lost efficacy maintenance or more exchange device before in plant efficiency.In this way, equipment failure that just can averting a calamity property and relevant repairing and replacement expense have also adapted to strict environmental legislation simultaneously.
The present invention is a kind of Wireless Acceleration Sensor principle and device.It has gathered sensor technology, radio-frequency technique, network technology and commercial Application technology, has self-organization, arranges flexible and inherent intelligent processing capacity fast.Consider these, the present invention will play an important role making on highly reliable and the industrial monitoring system with self-recovery ability.
[summary of the invention]
The objective of the invention is to overcome the deficiency of prior art, a kind of Wireless Acceleration Sensor that is used for vibration monitoring is provided; Characteristics such as it has flexibly, low-power consumption, embedding data-handling capacity.Simultaneously, it has characteristics such as identical high frequency sound, high precision with the wired formula acceleration transducer that is used for the industrial vibration monitoring again.
The objective of the invention is to realize through following technical scheme:
A kind of Wireless Acceleration Sensor that is used for vibration monitoring is made up of hardware and software two parts; Its notice is that hardware comprises control circuit board, Wireless Acceleration Sensor housing, piezoelectric acceleration transducer, powerful magnetic support, lithium battery group and antenna.Hierarchical design is adopted in the establishment of software, is divided into network layer, MAC layer and Physical layer.
Described control circuit board is positioned at the cavity of dividing plate, connecting cylinder and the base formation of Wireless Acceleration Sensor housing.The lithium battery group is positioned at the cavity of sensor housing end cap and dividing plate formation.End cap adopts with dividing plate and is threaded.The lithium battery group is supplied power to control circuit through the via hole on the dividing plate.Dividing plate and connecting cylinder adopt interference fit to link together, and treat after the assembled welded together again.Antenna is fixed on the connecting cylinder through nut, and links to each other with control circuit.Connecting cylinder is connected through interference fit with base, welding again after the assembled.Base is threaded with piezoelectric acceleration transducer passes through, welding again after the assembled.Piezoelectric acceleration transducer 2 and powerful magnetic support 3 are through being threaded.Connect referring to accompanying drawing 1 in detail.
Described control circuit board is accomplished the analog to digital conversion of analog acceleration signal, pre-service digital acceleration information, and result is transmitted to follow-up receiving trap through radio circuit.Control circuit is made up of feed circuit, microcontroller operating circuit and radio circuit.The 6v power supply that feed circuit are supplied with outside lithium battery group is sent into the voltage stabilizing chip through diode.The voltage stabilizing chip arrives 3.3v with the 6v level conversion, to guarantee the microcontroller steady operation.For guaranteeing the subsequent conditioning circuit operate as normal, added electric capacity in the feed circuit with filtering and accumulation of energy function.The microcontroller operating circuit is used to guarantee the operate as normal of controller self, comprises guaranteeing stable electric capacity, external crystal oscillation circuit and the external reset circuit of controller power supply.The external crystal oscillation circuit of controller is that controller provides the stable clock signal.Reset circuit clamps down on the control level that resets of controller at high level, keeps the operate as normal of controller.Radio circuit is used for the conversion of signals of controller input is become radiofrequency signal output.
Described Wireless Acceleration Sensor housing is made up of 4 parts, is respectively end cap 4, dividing plate 5, connecting cylinder 6 and base 7, and material is stainless steel.End cap and dividing plate adopt and are threaded, and the cavity of formation is used to place the lithium battery group, such connection easy design the replacing of lithium battery group.Screw thread glue sealing and reinforcing is adopted in the threaded connection place, plays the waterproof and dustproof protective effect to electric battery.In addition, the volume of cavity is with reference to the design of the volume of lithium battery group, be equipped with auxiliary clamping part after, electric battery mobile by strict restriction in cavity avoided the influence of long-term vibration to electric battery.Be designed with a 4mm diameter through hole on the dividing plate, supply the electric battery lead-in wire through supplying power to control circuit board.Simultaneously, also have the through hole of 3 2mm diameters on the dividing plate, screw passes this hole control circuit board and dividing plate is fixed up.The sealed cavity that dividing plate, connecting cylinder and base constitute is used for the installation and control circuit board.Dividing plate is with welded together again after connecting cylinder tentatively is connected through interference fit.The through hole that a 7mm diameter is arranged on the connecting cylinder supplies to fix up an aerial wire 1 socket.Connecting cylinder is with welded together again after base also tentatively is connected through interference fit.Base and sensor 2 adopt thread locking adhesive to seal and reinforce through being threaded during connection.Reliable in order to guarantee to connect, base and sensor are after being threaded, at faying face employing reinforcement of weld.After the assembled, silica gel sealing is all adopted in the antenna socket hole on the cable-through hole on the dividing plate, mounting hole and the connecting cylinder, and the protection control circuit board plays the effect of waterproof and dustproof.The housing of being processed into according to this Analysis of Nested Design scheme has reduced the influence of additional mass to transducer sensitivity as far as possible.
Described piezoelectric acceleration transducer, lithium battery group, antenna and powerful magnetic support are matured product.Wherein piezoelectric acceleration transducer is the induction element of vibration signal, can change the acceleration transducer of suitable range and precision according to different application scenarios.
Described software systems are divided into network layer, MAC layer and Physical layer.Communicating by letter between network layer management of sensor node and Centroid safeguarded the normal operation of whole network.MAC layer is the telecommunication media between network layer and the Physical layer.Physical layer has been done initial configuration to the basic module in the sensor node.After program brings into operation, at first call the Physical layer utility function basic module is carried out the initialization setting, get into listen mode then.After Wireless Acceleration Sensor is received correct host computer instruction under the listen mode; To get into normal mode of operation; Call the MAC layer utility function afterwards and handle the information receive, call communicating by letter of the processing of network layer utility function and host computer and other nodes at last.Referring to accompanying drawing 2.
The function of the network layer in the said software systems be the management of sensor node with Centroid between communicate by letter, safeguard the normal operation of whole network.Network layer can the identification center node communication format, make corresponding reaction according to the different command control Wireless Acceleration Sensor node of receiving from Centroid.The order of Centroid comprises: wake up, communicate by letter and shake hands.Wake when instruction up receiving, network layer control sensor node changes duty over to by listening state, and waits for the subsequent instructions of Centroid.After the time-delay of certain hour, if receiving subsequent commands or subsequent commands, the Wireless Acceleration Sensor node do not make mistakes, network layer will be controlled Wireless Acceleration Sensor and get into listening state once more.If at the appointed time, sensor node has been received communication instruction, and network layer will be controlled the Wireless Acceleration Sensor node and get into corresponding data acquisition and treatment mechanism.If received the instruction of shaking hands in the stipulated time, network layer will be controlled the Wireless Acceleration Sensor node and return the sensor number of oneself.
MAC layer in the said software systems is the telecommunication media between network layer and the Physical layer.Defined the utility function of visit piezoelectric acceleration transducer and radio-frequency module in the MAC layer.The utility function of visit acceleration transducer has defined acceleration information acquisition, sampling number and emergency response mechanism.The utility function of visit radio-frequency module has defined the form of radio communication, verification mode and corresponding treatment mechanism.Also define the processing function of acceleration information in the MAC layer, the raw data of analog to digital conversion gained has been done filtering and verification, improved data accuracy, reduced volume of transmitted data and power consumption.
Physical layer in the said software systems has been done initial configuration to the basic module in the Wireless Acceleration Sensor node.The system kernel utility function has defined parameters such as system clock, core voltage, port match.The analog-to-digital conversion module utility function has defined reference voltage, SF, sample port and the sampling interrupt processing mechanism etc. that finishes.The radio-frequency module utility function has defined parameters such as wireless communication bandwidth, rf frequency, output power signal, modulation demodulation system, communication verification.The initialized groundwork of software systems is exactly a parameter initialization of accomplishing Physical layer, and after this each functional module of Wireless Acceleration Sensor node just can operate as normal.
Compared with prior art, good effect of the present invention is:
Above-mentioned Wireless Acceleration Sensor case design scheme has structure characteristics light and handy, easy to assembly, is easy to realize mass production and layouts on a large scale.Adopt above-mentioned software system design, can reduce the power consumption of sensor greatly, improve the serviceable life of sensor.
[description of drawings]
Fig. 1 is a Wireless Acceleration Sensor hardware system synoptic diagram;
Fig. 2 constitutes synoptic diagram for the Wireless Acceleration Sensor software systems;
Being labeled as in the accompanying drawing: 1 antenna, 2 sensors, 3 powerful magnetic supports, 4 end caps, 5 dividing plates, 6 connecting cylinders, 7 bases.
[embodiment]
The present invention below is provided a kind of embodiment that is used for the Wireless Acceleration Sensor of vibration monitoring.
This type Wireless Acceleration Sensor is to develop for the demand that satisfies the monitoring of industrial group of pump and relevant industries vibration equipment.Characteristics such as it is bigger that industry group of pump vibration monitoring has data volume with respect to indoor environment monitoring, civil engineering work monitoring, agricultural monitoring etc., and real-time property and accuracy requirement are higher, and power consumption is bigger.Be limited by the mounting condition and the various dangerous operating mode of industry spot, wireless senser can only adopt the powered battery of finite energy, thereby has limited the level of power consumption and the arithmetic capability of sensor, has brought very big challenge to design.The present invention will address the above problem from following concrete embodiment.
It at first is the Wireless Acceleration Sensor System Software.The software systems that adopt the stratification design are to reduce the major measure of sensor power consumption.Because the restriction of energy, the industrial group of pump monitoring system most of the time all is in the state of dormancy or monitoring, and this ratio usually accounts for more than 99% of work period, even some system only gathers 1～2 every day, gathers the several seconds at every turn.Consider above factor, software systems are divided into two kinds with the duty of Wireless Acceleration Sensor: listening state and duty.Under the listening state, sensor is whenever just opened the receiving function of radio-frequency module, the order that the listening center node transmits at a distance from 10 seconds.If received the right instructions that Centroid is sent in during this period of time, then system gets into corresponding treatment mechanism, if during do not receive instruction or the instruction errors of receiving, then system gets into next listening period.Be the length of one's sleep 10 seconds during this time; This moment, piezoelectric acceleration transducer was in power failure state; Microcontroller and radio-frequency module also all are under the sleep pattern; Only depend on an inner low-power consumption clock of microcontroller to keep a chronograph mechanism of 10 seconds, so that timing in 10 seconds waken system, the letter of listening center node again later.In 10 seconds sleep period, the electric current of total system is reduced to 0.5mA, and power consumption is 1.65 milliwatts.In 8 milliseconds of monitoring phases, the current drain of total system is 30mA, and power consumption is 99 milliwatts.Average power consumption in the so whole listening period is merely 1.73 milliwatts.Lithium battery with a joint 0.5Ah is an example, and this type Wireless Acceleration Sensor was worked 40 days under listening state.If in listening period, received the right instructions of Centroid, then Wireless Acceleration Sensor gets into duty.If what receive is the instruction of gathering acceleration information, then that piezoelectric acceleration transducer is got is electric for microcontroller, and the time-delay certain hour, stable to guarantee the sensor power supply.Time-delay later program gets into analog to digital conversion mechanism down in the restriction of preset collection quantity or acquisition time, the data that conversion finishes again the process down-stream declare mistake and Filtering Processing, finally be stored in the microcontroller.After receiving the continuous teletype command of Centroid, sensor node sends mass data to Centroid in batches, just gets into listen mode after finishing once more.When getting into listen mode by mode of operation, piezoelectric acceleration transducer is dead electricity once more, and microcontroller and radio-frequency module also will get into sleep pattern.Whole data collection continues about 7 seconds with transmitting the work period, and average power consumption is 66 milliwatts.Consider 1～2 time frequency acquisition every day, such power consumption is an acceptable.If what receive is the instruction of shaking hands, Wireless Acceleration Sensor will be returned the numbering of oneself.This instruction is a Centroid maintenance sensor network for ease, in time finds the failure sensor node.The whole handshake process cycle continues about 10 milliseconds, and average power consumption is 99 milliwatts.Consider the frequency of shaking hands of Centroid every day 1～2, such energy consumption also is an acceptable.Handshake process is in the cycle, and piezoelectric acceleration transducer is in power failure state.After the handshake process cycle receives, system will get into listening state once more.
Next is the design of control circuit board.Wireless Acceleration Sensor selects for use the integrated chip of microprocessor and radio frequency chip as controller.This cake core has excellent low power capabilities, and innerly embeds radio frequency chip, thereby has saved space on interface resource and the limited plate.Through comparison, if adopt microcontroller and the discrete design proposal of radio frequency chip, the area of control panel will exceed about 10% than now.The power pack of control circuit board adopts one-level voltage stabilizing chip, and the 6v power supply that the lithium battery group is provided is reduced to 3.3v supply microcontroller.The radio-frequency module of Wireless Acceleration Sensor needs the electric current supply about 30mA when getting into monitoring or emission state by sleep pattern, and the total current drain under the sleep pattern is 0.5mA.The current break of moment can cause feed circuit unstable, and output voltage descends, when serious even can cause microcontroller generation low level to reset.In order to address this problem; Electric capacity in the controller feed circuit has been carried out reasonable disposition, through calculating and verification experimental verification, under the situation that current break takes place; They can play good current compensation effect, and also Be Controlled is in the reasonable scope in the decay of supply voltage.Radio circuit part is strict with design specifications, and on this basis, according to strict radio circuit The matching analysis result the radio circuit parameter has been done fine tuning, obtained the radio circuit parameter of an optimization, has reduced energy consumption unnecessary on the radio circuit.Because energy-conservation needs, the Wireless Acceleration Sensor most of the time is operated under the listen mode, and the piezoelectric acceleration transducer of this moment need not power supply.The output port power supply by microcontroller of piezoelectric acceleration transducer, under listen mode, microcontroller makes the power supply port output low level of piezoelectric acceleration transducer, the sensor dead electricity, thus reach purpose of energy saving.
Once more, industrial group of pump vibration monitoring has proposed very high requirement to the communication quality of Wireless Acceleration Sensor.The rotating speed of considering industrial motor or pump is generally at 3000～5000r/min; Guaranteeing sampling precision and reducing under the prerequisite of software systems resource consumption as far as possible; The analog to digital conversion rate of having set in the microcontroller is 0.8ksps, can satisfy the vibration monitoring demand under the general application scenario.Consider that simultaneously analog-to-digital precision is 14, will produce the data volume of 1.6kB p.s..Adopt poll mode in batches to transmit data among the present invention, and be provided with wrong retransmission mechanism at the Centroid place and guarantee that acceleration information transmits accurately.When the center node need carry out data acquisition to one or more sensor nodes, just the numbering embedding of one or more sensor nodes is sent in the packet and send.These sensors that are in listening state are received the work period that just gets into data acquisition after the instruction, data acquisition and dispose after, sensor node just waits for a period of time.During this period of time, Centroid is with each sensor node of poll.The sensor node of receiving the poll instruction can send the data of handling well to Centroid in batches, and the Centroid that is in receive status can be judged the check bit that receives data successively, to guarantee the correctness of the data of being received.If fail to receive proper data owing to reasons such as interference cause Centroid, Centroid will trigger the retransmission mechanism of respective sensor node, the continuous follow-up data that passes.After treating that a sensor node data transmission finishes, Centroid will trigger other sensor nodes successively and upload data.Such communication mechanism just can guarantee the reliability of acceleration information transmission.
At last, Wireless Acceleration Sensor has been passed through strict Electromagnetic Interference Test, can guarantee the operate as normal under complex electromagnetic environment.Software systems inside has also embedded the house dog program, prevents that phenomenons such as deadlock from appearring in software under unexpected situation, further improved the robustness of system.In addition, threaded hole is arranged at the piezoelectric acceleration transducer bottom.Therefore, can use powerful magnetic support with the measuring point place of Wireless Acceleration Sensor sorption at pump, and can be aided be threaded, modes such as glue or welding, thereby guarantee to connect reliable.The mode that the powerful magnetic support of this dependence is installed is particularly useful for the provisional occasion that installs and measures.
The above only is a preferred implementation of the present invention; Should be pointed out that for those skilled in the art, under the prerequisite that does not break away from the present invention's design; Can also make some improvement and retouching, these improvement and retouching also should be regarded as in protection scope of the present invention.
Claims (9)
1. a Wireless Acceleration Sensor that is used for vibration monitoring is made up of hardware and software two parts; It is characterized in that hardware comprises control circuit board, Wireless Acceleration Sensor housing, piezoelectric acceleration transducer, powerful magnetic support, lithium battery group and antenna; Hierarchical design is adopted in the establishment of software, is divided into network layer, MAC layer and Physical layer.
2. a kind of Wireless Acceleration Sensor that is used for vibration monitoring as claimed in claim 1 is characterized in that, in described hardware, described control circuit board is positioned at the cavity of dividing plate, connecting cylinder and the base formation of Wireless Acceleration Sensor housing; The lithium battery group is positioned at the cavity of sensor housing end cap and dividing plate formation; End cap adopts with dividing plate and is threaded; Dividing plate and connecting cylinder adopt interference fit to link together, and treat after the assembled welded together again; Antenna is fixed on the connecting cylinder through nut, and links to each other with control circuit; Connecting cylinder is connected through interference fit with base, welding again after the assembled; Base is threaded with piezoelectric acceleration transducer passes through, welding again after the assembled; Piezoelectric acceleration transducer and powerful magnetic support are through being threaded.
3. a kind of Wireless Acceleration Sensor that is used for vibration monitoring as claimed in claim 1; It is characterized in that; In described hardware; Described control circuit board is accomplished the analog to digital conversion of analog acceleration signal, pre-service digital acceleration information, and result is transmitted to follow-up receiving trap through radio circuit; Control circuit is made up of feed circuit, operating circuit and radio circuit.
4. a kind of Wireless Acceleration Sensor that is used for vibration monitoring as claimed in claim 1; It is characterized in that in described hardware, described Wireless Acceleration Sensor housing is made up of 4 parts; Be respectively end cap, dividing plate, connecting cylinder and base, material is stainless steel; End cap adopts with dividing plate and is threaded, and the cavity of formation is used to place the lithium battery group, and screw thread glue sealing and reinforcing is adopted in the threaded connection place; The sealed cavity that dividing plate, connecting cylinder and base constitute is used for the installation and control circuit board.
5. a kind of Wireless Acceleration Sensor that is used for vibration monitoring as claimed in claim 4 is characterized in that, is designed with a 4mm diameter through hole on the described dividing plate, supplies the electric battery lead-in wire through supplying power to control circuit board; Also have the through hole of three 2mm diameters on the dividing plate, screw passes this hole control circuit board and dividing plate is fixed up.
6. a kind of Wireless Acceleration Sensor that is used for vibration monitoring as claimed in claim 1 is characterized in that, in described software, the normal operation of whole network is safeguarded in communicating by letter between network layer management of sensor node and Centroid; MAC layer is the telecommunication media between network layer and the Physical layer; Physical layer has been done initial configuration to the basic module in the sensor node; After program brings into operation, at first call the Physical layer utility function basic module is carried out the initialization setting, get into listen mode then; After Wireless Acceleration Sensor is received correct host computer instruction under the listen mode; To get into normal mode of operation; Call the MAC layer utility function afterwards and handle the information receive, call communicating by letter of the processing of network layer utility function and host computer and other nodes at last.
7. a kind of Wireless Acceleration Sensor that is used for vibration monitoring as claimed in claim 1; It is characterized in that; In described software, the network layer in the said software systems be the management of sensor node with Centroid between communicate by letter, safeguard the normal operation of whole network; Network layer can the identification center node communication format, make corresponding reaction according to the different command control Wireless Acceleration Sensor node of receiving from Centroid; The order of Centroid comprises: wake up, communicate by letter and shake hands; Wake when instruction up receiving, network layer control Wireless Acceleration Sensor node changes duty over to by listening state, and waits for the subsequent instructions of Centroid; After the time-delay of certain hour, if receiving subsequent commands or subsequent commands, the Wireless Acceleration Sensor node do not make mistakes, network layer will be controlled Wireless Acceleration Sensor and get into listening state once more; If at the appointed time, the Wireless Acceleration Sensor node has been received communication instruction, and network layer will be controlled the Wireless Acceleration Sensor node and get into corresponding data acquisition and treatment mechanism; If received the instruction of shaking hands in the stipulated time, network layer will be controlled the Wireless Acceleration Sensor node and return the sensor number of oneself.
8. a kind of Wireless Acceleration Sensor that is used for vibration monitoring as claimed in claim 1 is characterized in that, in described software, the MAC layer in the said software systems is the telecommunication media between network layer and the Physical layer; Defined the utility function of visit piezoelectric acceleration transducer and radio-frequency module in the MAC layer; The utility function of visit Wireless Acceleration Sensor has defined acceleration information acquisition, sampling number and emergency response mechanism; The utility function of visit radio-frequency module has defined the form of radio communication, verification mode and corresponding treatment mechanism; Also defined the processing function of acceleration information in the MAC layer, the raw data of analog to digital conversion gained has been done filtering and verification.
9. a kind of Wireless Acceleration Sensor that is used for vibration monitoring as claimed in claim 1 is characterized in that in described software, the Physical layer in the said software systems has been done initial configuration to the basic module in the Wireless Acceleration Sensor node; The system kernel utility function has defined system clock, core voltage, port match parameter; The analog-to-digital conversion module utility function has defined reference voltage, SF, sample port and the sampling interrupt processing mechanism that finishes; The radio-frequency module utility function has defined wireless communication bandwidth, rf frequency, output power signal, modulation demodulation system, communication checking parameter; The initialized groundwork of software systems is exactly a parameter initialization of accomplishing Physical layer, and after this each functional module of sensor node just can operate as normal.
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| CN201210090437XA CN102662081A (en) | 2012-03-30 | 2012-03-30 | A wireless acceleration sensor for vibration monitoring |
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| WO2018151805A1 (en) * | 2017-02-16 | 2018-08-23 | Watlow Electric Manufacturing Company | Compact modular wireless sensor |
| CN109632069A (en) * | 2019-01-23 | 2019-04-16 | 杭州嘉诚机械有限公司 | Portable speed reducer vibration measurement module and measurement method |
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Application publication date: 20120912 |