CN103884371B - Trouble-shooter based on WIA PA wireless vibration instrument and method - Google Patents
Trouble-shooter based on WIA PA wireless vibration instrument and method Download PDFInfo
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- CN103884371B CN103884371B CN201210560416.XA CN201210560416A CN103884371B CN 103884371 B CN103884371 B CN 103884371B CN 201210560416 A CN201210560416 A CN 201210560416A CN 103884371 B CN103884371 B CN 103884371B
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Abstract
The present invention relates to a kind of trouble-shooter based on WIA PA wireless vibration instrument, EPA is connected with host computer, server, radio network gateway, and radio network gateway carries out radio communication with the wireless vibration instrument being arranged on industrial equipment.Method includes: wireless vibration instrument enters WIA wireless network；If wireless vibration instrument is first use, then host computer setting diagnosis procedure parameter issues, and this instrument preserves diagnosis procedure parameter；Use if not first, then wireless vibration instrument judges whether the operation time reaches the collecting and refreshing data cycle of self；Not up to then terminate this diagnosis；Reach, start wireless vibration instrument and complete operation；Data after host computer reception process, and issue end order；Then data are uploaded to data base and are used for accident analysis.The present invention can solve self-power wireless instrument low-power consumption demand, to improve instrument battery service life.
Description
Technical field
The present invention relates to a kind of method and device performing equipment fault diagnosis.Device performs fault diagnosis based on vibration,
And by WIA-PA wireless network transmissions vibration data to host computer, realize high level diagnostics further.
Background technology
In the modern enterprises such as oil, chemical industry, metallurgy and electric power, the equipment such as blower fan, compressor, pump, motor is all crucial
The tool of production, these equipment are carried out state-detection and fault diagnosis and work, ensure the operation that equipment is safe and reliable, Ke Yiqu
Obtain huge economic benefit and social benefit.Vibration has destructiveness to the equipment in these work, the imbalance of such as rotor
Or impact, the rolling between part and phase mutual friction, the gap produced between part or loosening, the peeling of piece surface generation or crackle
Etc..These vibrations will cause element fault or inefficacy.
Vibration instrument by be directly mounted at machine surface vibrating sensor sensor device produce vibration and noise signals,
Identify that abnormal vibrations amplitude also combines host computer data base's Judging fault part and fault type, thus maintenance or change fault or
The parts that performance reduces, it is to avoid the loss that machine halt trouble causes.Such as, installing instrument to deoxidation pump, detection is de-in real time
The vibration of oxygen pump, analyze vibration signal find the potential fault of pump as uneven, misalign, bearing fault etc., it is achieved base
Maintenance in state.
Vibration diagnosis can find the parts that fault or performance reduce in advance, changes in advance or keeps in repair, and reduces and safeguards into
This and avoid shutting down suddenly the economic loss caused.Traditional wire instrument installation wiring is complicated, and cable is purchased, laid and safeguard into
This height.Wireless instrument based on WIA-PA network can well meet the demand of system monitoring.Intelligent wireless network WIA
(Wireless Networks for Industrial Automation) marks based on short-distance wireless communication IEEE802.15.4
Standard, uses free frequency band, solves the multipath effect caused wireless signal reflection, scattering at large-scale apparatus, metallic conduit etc., with
And the electromagnetic noise that the operating of motor, apparatus produces is to radio communication interference, it is provided that highly reliable, real-time radio Communications service.Intelligence
Wireless network WIA technology is particularly well-suited to Industry Control and factory automation processes and controls, and be widely used in oil, chemical industry,
The fields such as metallurgy, mine.
Summary of the invention
For the deficiencies in the prior art, the present invention provides a kind of method and device performing equipment fault diagnosis.
The present invention be the technical scheme is that fault based on WIA-PA wireless vibration instrument is examined for achieving the above object
Disconnected device, EPA is connected with host computer, server, radio network gateway, and radio network gateway sets for large-scale rotation with being arranged on
Standby upper wireless vibration instrument carries out radio communication.
Described equipment includes pump, motor, compressor.
Described wireless vibration instrument includes: microcontroller and reset circuit, clock circuit, memory circuitry, A/D change electricity
Road, radio receiving transmitting module connect；Vibrating sensor is connected with the input of signal processing circuit, the outfan of signal processing circuit
It is connected with the analog input end of A/D change-over circuit.
Method for diagnosing faults based on WIA-PA wireless vibration instrument, comprises the following steps:
Gateway search wireless vibration instrument, wireless vibration instrument enters WIA wireless network；
If wireless vibration instrument is first use, then host computer sets diagnosis procedure parameter and is issued to this instrument, this instrument
Table preserves diagnosis procedure parameter；Use if not first, then wireless vibration instrument judges whether the operation time reaches self
The collecting and refreshing data cycle；Not up to then terminate this diagnosis；Reach, start wireless vibration instrument and complete single treatment operation；
Host computer receives the data after wireless vibration instrument processes by EPA, and issues end order to wireless
Vibration instrument；Then data are uploaded to Fault Diagnosis Database and are used for accident analysis, it is achieved the fault of wireless vibration instrument is examined
Disconnected.
Described diagnosis procedure parameter includes instrument refresh rate, instrumentation pattern, equipment under test fundamental frequency, accident analysis frequency
Spectrum frequency, data sampling frequency, data sampling length.
Described wireless vibration instrument list processing function comprises the following steps:
Microcontroller in wireless vibration instrument according to be loaded into data sampling frequency and data sampling length by instrument
The voltage signal of the sensor that A/D change-over circuit is received is converted to sensor feedback data and carries out data scaling and sensor shape
The judgement of state:
Data scaling is specially and sensor feedback data is converted to vibration acceleration signal；
According to sensor feedback data, the judgement of sensor states is particularly as follows: judge that whether sensor is at normal condition；As
Abnormal, do not start instrumentation；If normal, then use Fourier transformation method that vibration data is converted into frequency spectrum；
Wireless vibration instrument is sent by radio receiving transmitting module request WIA wireless network and once gathers operation result；Data
After being transmitted, wireless vibration instrument process terminates and enters resting state.
Vibration data is converted into frequency spectrum data particularly as follows: by vibration acceleration signal by described employing Fourier transformation method
Be converted to the vibration amplitude of time domain, and apply fast Fourier transform to obtain the frequency spectrum of frequency domain.
Described collection operation result includes vibration amplitude data and frequency spectrum.
The described fault diagnosis result that obtains comprises the following steps:
Vibration amplitude data summarization according to each collecting and refreshing data cycle goes out vibration trend figure, sentences according to vibration threshold
Whether fixed have abnormal vibrations；If beyond threshold value, then this abnormal data input fault diagnostic data base being obtained failure cause, logical
The table number crossing instrument obtains trouble point.
The invention have the advantages that and advantage:
The most whole device be applied to equipment health status detection, low cost, high efficiency raising parts maintenance cost and
Efficiency.
2. wireless vibration instrument can intelligence realizes the local main power consumption chip power control of instrument, wireless module power supply controls
And probe power controls function, and then solve self-power wireless instrument low-power consumption demand, to improve the instrument battery operated longevity
Life.
Accompanying drawing explanation
The trouble-shooter system architecture diagram of Fig. 1 present invention；
Fig. 2 realizes the wireless vibration instrument networking schematic diagram of this device；
Fig. 3 realizes the wireless vibration appliance circuit structured flowchart of this device；
Fig. 4 realizes the wireless vibration instrumentation FB(flow block) of this device；
The trouble-shooter working-flow block diagram of Fig. 5 present invention.
Detailed description of the invention
Below in conjunction with the accompanying drawings and embodiment the present invention is described in further detail.
A kind of method for diagnosing faults based on WIA-PA wireless vibration instrument and device, including being directly mounted at machine surface
For the vibrating sensor of sense vibration signal, perform vibration signals collecting and the controller of process, be connected to WIA-PA wireless
The radio receiving transmitting module of network, carrying High Fault identification and the host computer of diagnostic method.
The invention provides a kind of method for diagnosing faults and device, vibration instrument based on WIA-PA wireless network realizes examining
Disconnected data acquisition and process, diagnostic monitoring upper computer software realizes fault diagnosises based on data.The present invention is used for monitoring industry
Health status in equipment work, identifies fault and the parts of performance reduction and keeps in repair before fault occurs or change.
Fig. 1 is to include monitoring the wireless vibration instrument 19 of fault and the method for diagnosing faults of monitoring diagnosis system 11 and device
System topological figure.Wireless vibration instrument is connected to monitored equipment 23,24,25 by sensor interface 20,21,22, uses
Acceleration transducer sense vibrations signal.Monitored equipment can be the equipment such as pump, motor, compressor.Monitoring diagnosis system
11 comprise industrial computer, operating system and accident analysis application software, data storage software etc., will be by WIA wireless network
Close vibration data storage, the computing analyzing sent here on 15, and then identify fault components and parts and fault level.Backstage WIA services
Device 12, EPA 14, WIA radio network gateway 15, wireless vibration instrument 19 forms WIA wireless network.Backstage WIA server 12
Comprise computer, operating system and user application software, file journalization etc..It is used for the configuration to equipment, under network
The control of equipment, detection analysis of information collection, the function such as storage of data.User will be corresponding by WIA server user's end
Information command is issued to the instrument in WIA wireless network.WIA radio network gateway connects into EPA by network interface 13
14, and then communicate with backstage WIA server 12 and monitoring vibrational system 11.One gateway can by wireless receiving and dispatching signal 16 even
Connect multiple wireless vibration instrument, it is simple to realize factory's multicomputer monitoring of tools networking application.Such as, the wireless vibration instrument in figure
17, the health status monitoring that can realize deoxidation pump group motor and axle such as 18,19, and will be each by accessing WIA wireless network
Delivering to WIA radio network gateway 15 on the vibration data of test point, data are uploaded to monitoring and diagnosis by EPA by gateway again
System 11, completes whole monitoring system function.
Fig. 2 is the wireless vibration instrument networking schematic diagram realizing this device.The deoxidation pump assembly in such as certain steam power plant workshop,
Vibrating sensor 31 is directly installed on equipment under test 25 control point, as motor X to and Y-direction.Wireless vibration instrument 19 is led to
Crossing sensor interface 30 and be connected to vibrating sensor, sensor interface 30 comprises the telecommunications of probe power and sense vibration
Number.Wireless vibration instrument 19 provides working sensor power supply, and receives the signal of telecommunication of sensor feedback.Instrument is with sensor nearby
Install, in case noise jamming and loss in stop signal transmitting procedure.Signal is through the signal processing mould of wireless vibration instrument this locality
After block 28 and data processing module 27 process, it is uploaded to the WIA radio network gateway in deoxidation pump assembly workshop via WIA network 29, then
It is connected to background server and diagnosis host computer in control room, it is achieved the health status of unit is monitored, letter by network interface
Change field power supply and signal transmission wiring, cost-effective.
Fig. 3 is the circuit structure block diagram of the wireless vibration instrument 19 realizing this device.By microcontroller 32, vibrating sensor
31, signal processing circuit 37, A/D change-over circuit 36, radio receiving transmitting module 39, power circuit 38, wireless module power supply 41, sensing
Device power supply 40 circuit module such as grade forms.Probe power 40 module of instrument provides working power, module for vibrating sensor 31
Inside it is designed with power control function to guarantee that instrument low-power consumption works.In instrument, signal processing circuit 37 realizes signals collecting, hard
The functions such as part filtering and operation amplifier, so that signal adapts to the input demand of A/D change-over circuit 36.A/D change-over circuit 36
Realizing analogue signal to change and detection function to digital signal, transformation result is through microcontroller 32 and A/D change-over circuit 36
Between number bus transmission.Microcontroller 32 completes vibration amplitude computing, and calculates according to known sample frequency and sampling length
Vibration signals spectrograph data.Microcontroller 32 peripheral circuit includes reset circuit 33, clock circuit 34, memory circuitry 35 and
Other microcontroller mini system circuit.Memory circuitry 35 comprises caching intermediate data storage device and loading instrument list procedure and configuration
The memorizer of parameter.Microcontroller 32 starts data acquisition, computing according to being pre-configured with parameter and passes through peripheral wireless receiving and dispatching mould
Block 39 transfers data to WIA wireless network.Radio receiving transmitting module 39 power supply is provided by instrument equally, and instrument is designed with power supply control
Function can realize wireless module low-power consumption work according to WIA network state.Meanwhile, work is joined by command information and instrument
Confidence breath is all issued by WIA wireless network, and microcontroller 32 receives and according to proprietary protocol resolve command and renewal instrument basis
Ground allocation list, makes user be arranged to preserve.
Fig. 4 is the wireless vibration instrumentation FB(flow block) realizing this device.It is designed with power supply in wireless vibration instrument 19
Management function, controls according to corresponding configuration (instrumentation pattern is battery saving mode or normal mode) or user instruction information
Instrument program starts 45.After instrument starts, instrument need to be performed and initialize 46, comprise and load the startup program of microcontroller 32 and carry
Enter configuration parameter information, including instrumented data frequency acquisition, data acquisition length, Refresh Data rate, analyzed equipment fundamental frequency, divide
Analysis frequency, instrumentation pattern, identify instrument current operation instruction etc..Initialization complete after in instrument microcontroller according to load
The sample frequency entered and length start data acquisition 47 process, and gatherer process includes that data scaling and sensor states judge,
Sensor states judges to judge that sensor bias voltage is the most normal exactly；And then determine whether that starting data processes 48 processes i.e.
If sensor is not in place or abnormal, do not starts data and process.Data scaling is will to be connect according to the A/D converter in instrument
The voltage signal received is converted to corresponding vibration acceleration signal；Judge that sensor is the most in place and power supply is the most normal, as different
Often, instrumentation is not started.Data process 48 and mainly vibration data are converted into frequency spectrum data, including digital filtering, FFT
The data operation Processing Algorithm such as (fast Fourier transform), wavelet transformation, first according to analyzing fundamental frequency and frequency and sampling
Frequency, sampling length carry out FFT, and transformation results is completed data compression through wavelet transformation and then transmitted by WIA network；Tool
Body is to gather sensing data according to sample frequency and sampling length, and the time domain data array obtained is according to calculating vibration width
Value；And apply fast Fourier transform FFT to obtain meeting equipment under test fundamental frequency and the frequency spectrum of accident analysis frequency spectrum frequency: application
Fast Fourier transform completes the time domain conversion to frequency domain data, and then according to frequency spectrum failure judgement reason；Wherein, sample frequency
Setting value be at least three times of equipment under test rotating speed, fundamental frequency is equipment under test rotating speed, and accident analysis frequency spectrum frequency needs specialty
Personnel there may be form according to device type and fault and are set.
After completing processing procedure, instrument starts connection WIA wireless network process 49 by radio receiving transmitting module 39, asks net
Network sends and once gathers operation result.WIA network data transmission proprietary protocol is followed in data transmission 50, can for improving data transmission
By property, in host-host protocol, design CRC check step by step and retransmission mechanism, and in the corresponding warning of user api design and day
Will information, to facilitate whole diagnostic system to safeguard.Completing data transmission and after handshaking information completes alternately, instrument program is hung up,
Enter 51 processes of end.Now, in addition to management controls function, entrance resting state is to save power consumption, under program waits for whole instrument
One-shot.
Fig. 5 is the trouble-shooter working-flow block diagram of the present invention.From the beginning of starting WIA gateway control end software
53, first complete WIA network configuration 54, then according to instrument wireless ID search wireless vibration instrument networking 55, instrument is with wireless
Gateway completes handshake communication.(user refers to use the engineer of this diagnostic system to user；According to whether be to install and use for the first time
This diagnostic system judges whether to revise procedure parameter) it is first determined whether there is diagnosis procedure parameter to need amendment, modified as needed to, hold
Row 56 issues parameter configuration and preserves parameter configuration 57；As being not required to amendment, then judge whether that meeting diagnostic data mining for vehicles refreshes week
Phase, be unsatisfactory for, directly terminate 60 this operation, satisfied then startup wireless vibration instrument 58 perform once-through operation.After completing operation
Host computer receives instrument return data, and issues end wireless vibration instrumentation order.After completing, data are uploaded to fault
Diagnostic software data base 59, uses for fault diagnosis and when checking historical data.Upload packet data Han vibration amplitude, and
Frequency spectrum data；Fault diagnosis software data base 59 goes out vibration trend figure according to the vibration amplitude data summarization of per refresh cycle, should
Figure shows vibration amplitude during normal operation of sensor state；Abnormal vibrations is determined whether there is according to vibration threshold；According to often brushing
The rumble spectrum data input fault diagnostic data base in new cycle, this data base is made up of the fault data of sensor, including frequency
Modal data and the failure cause of its correspondence, the therefore the most available failure cause of input spectrum data；Host computer passes through wireless vibration
The table number of instrument just can obtain trouble point.
Claims (1)
1. method for diagnosing faults based on WIA-PA wireless vibration instrument, it is characterised in that comprise the following steps:
Gateway search wireless vibration instrument (19), wireless vibration instrument (19) enters WIA wireless network；
If wireless vibration instrument (19) is first use, then host computer (11) sets diagnosis procedure parameter and is issued to this instrument,
This instrument preserves diagnosis procedure parameter；Use if not first, then wireless vibration instrument (19) judges whether the operation time reaches
The collecting and refreshing data cycle to self；Not up to then terminate this diagnosis；Reach, start wireless vibration instrument (19) and complete
Single treatment operates；
Host computer (11) receives the data after wireless vibration instrument (19) processes by EPA (14), and issues end life
Make to wireless vibration instrument (19)；Then data are uploaded to Fault Diagnosis Database and are used for accident analysis, it is achieved wireless vibration
The fault diagnosis of instrument；
Obtain fault diagnosis result to comprise the following steps:
Vibration amplitude data summarization according to each collecting and refreshing data cycle goes out vibration trend figure, according to vibration threshold judgement is
No have abnormal vibrations；If beyond threshold value, then this abnormal data input fault diagnostic data base being obtained failure cause, passing through instrument
The table number of table obtains trouble point；
Described diagnosis procedure parameter includes instrument refresh rate, instrumentation pattern, equipment under test fundamental frequency, accident analysis frequency spectrum times
Frequency, data sampling frequency, data sampling length；
Described wireless vibration instrument (19) processes operation and comprises the following steps:
Microcontroller (32) in wireless vibration instrument (19) according to be loaded into data sampling frequency and data sampling length by instrument
In table the voltage signal of the sensor that A/D change-over circuit (36) is received be converted to sensor feedback data carry out data scaling and
The judgement of sensor states:
Data scaling is specially and sensor feedback data is converted to vibration acceleration signal；
According to sensor feedback data, the judgement of sensor states is particularly as follows: judge that whether sensor is at normal condition；Such as exception,
Do not start instrumentation；If normal, then use Fourier transformation method that vibration data is converted into frequency spectrum；
Wireless vibration instrument (19) is sent by radio receiving transmitting module (39) request WIA wireless network and once gathers operation result；
After data are transmitted, wireless vibration instrument (19) process terminates and enters resting state；
Vibration data is converted into frequency spectrum data particularly as follows: changed by vibration acceleration signal by described employing Fourier transformation method
For the vibration amplitude of time domain, and fast Fourier transform is applied to obtain the frequency spectrum of frequency domain；
Described collection operation result includes vibration amplitude data and frequency spectrum.
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| TW201633024A (en) * | 2015-03-06 | 2016-09-16 | Nat Univ Chin Yi Technology | Process machine sliding table monitoring system |
| TWI578134B (en) * | 2015-07-24 | 2017-04-11 | 國立勤益科技大學 | Linear slide bearing monitoring system |
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| CN110207810B (en) * | 2018-02-28 | 2021-11-30 | 常州路航轨道交通科技有限公司 | Axle box vibration detection system |
| CN108871434B (en) * | 2018-05-30 | 2024-05-31 | 北京必创科技股份有限公司 | Online monitoring system and method for rotating equipment |
| CN108645619B (en) * | 2018-07-25 | 2020-05-12 | 浙江福库工业科技有限公司 | Intelligent monitoring system for vibration of mechanical bearing |
| CN109163796A (en) * | 2018-09-10 | 2019-01-08 | 广州小楠科技有限公司 | Bearing in rotating machinery vibration data intelligence is capable of real-time acquisition and analysis system |
| US11184690B2 (en) * | 2018-12-07 | 2021-11-23 | Itt Manufacturing Enterprises Llc | Embedded system for vibration detection and analysis |
| CN114698072B (en) * | 2022-03-21 | 2024-04-26 | 沈阳中科奥维科技股份有限公司 | Low-power-consumption circuit of WIA-PA wireless vibration transmitter and control method |
| CN114719958A (en) * | 2022-03-21 | 2022-07-08 | 沈阳中科奥维科技股份有限公司 | Vibration monitoring system and method based on WIA-PA and 4G double wireless technology |
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