CN105974859A - Wireless monitoring system based on vibration sensor - Google Patents
Wireless monitoring system based on vibration sensor Download PDFInfo
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- CN105974859A CN105974859A CN201510519854.5A CN201510519854A CN105974859A CN 105974859 A CN105974859 A CN 105974859A CN 201510519854 A CN201510519854 A CN 201510519854A CN 105974859 A CN105974859 A CN 105974859A
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- vibrating sensor
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/048—Monitoring; Safety
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Abstract
The present invention provides a wireless monitoring system based on a vibration sensor. The system comprises an upper computer, a gateway module and at least one vibration sensor. The system employs a wireless network monitoring mode to build a wireless distributed vibration monitoring system, so that the cable wiring cost is saved, the maintainability is good, the system flexibility is high, the output time domain/frequency domain analysis data is selectable, the transition process is saved and the timeliness and the efficiency of the whole system are greatly improved while realizing the real-time monitoring of the operation of a mechanical device; and moreover, the vibration sensor employs a cylinder design, the bottom of the vibration sensor is provided with a circular hole and employs permanent magnet materials so as to have the convenient installation, the wide range of application and the greatly improved response range and real-time sampling rate.
Description
Technical field
The present invention relates to rotate dynamo-electric equipment running status monitoring technical field, specifically, relate to wireless monitor system based on vibrating sensor.
Background technology
Industrial processes are increasingly dependent on motor and associated machines high efficient and reliable, uniform running.The imbalance of machinery equipment, defect, securing member loosen and other abnormal phenomena is often converted into vibration, cause precise decreasing, and cause safety problem.If ignored, in addition to causing performance and safety problem, if causing equipment downtime to be repaired, production loss also will necessarily be brought.And there is small change in equipment performance, it is common that be difficult to prediction in time, accumulate over a long period and also can be quickly converted to great production loss.
At present, the system of condition monitoring to large rotating machinery bearing has carried out exploitation, test and experimentation both at home and abroad, but, still suffer from many defects, such as:
First, for the most ripe monitoring system based on wired connection, signalling channel many employings wire transmission many employings wire transmission mode between sensor signal and capture card, length of cable needs dozens or even hundreds of rice, but there is cable and lay complexity, relatively costly, maintainable poor, the shortcomings such as system flexibility difference, in the face of these problems, one selectable resolving ideas uses radio sensing network monitoring pattern wireless to build exactly, distributed vibration monitor system, but technology of wireless sensing network is the most immature, therefore, remain a need for the feasibility study that large rotating machinery bear vibration is monitored by application wireless sensor device.
Second, usually, any equipment has multiple vibration source, such as bearing defect, imbalance and gear engagement etc., the vibration source brought in addition with design, the such as vibration that boring machine or press produce in course of normal operation.Traditional wireless vibration sensor has single shaft, twin shaft and three axles, but they provide only time-domain signal, time-based analysis meeting produces the complicated wave form of comprehensive all these vibration sources, before carrying out fft analysis, the information that it provides is difficult to distinguish, and majority piezoelectric transducer solution relies on outside FFT(fast Fourier transform) calculate and analyze, host computer carries out frequency-domain analysis by specific software, this real-time not only making whole system and synchronicity have no possibility, and the work of major part additional designs is pushed outward towards equipment development business.
3rd, wireless vibration sensor before is cuboid mostly, for monitoring point with cambered surface on equipment, needs the most smooth contact area, very inconvenient during installation.And its function is the most single, frequency response range and real-time sampling rate are less, it is impossible to be configured according to practical situation, bad adaptability.
Summary of the invention
In order to solve the problems referred to above in current plant equipment operational monitoring, the present invention provides a kind of wireless monitor system based on vibrating sensor, and its concrete technical scheme is as follows:
Wireless monitor system based on vibrating sensor, including host computer, gateway module and at least one vibrating sensor, wherein:
Described host computer is connected by EPA with gateway module；
Vibrating sensor is gone forward side by side line frequency domain analysis for the online vibration obtaining machinery and temperature data；
Described vibrating sensor includes sensing unit and processor, and described sensing unit connects processor, described processor embedded RF transceiver by mating connector, is connected with antenna, for gateway module transceiving data；
Gateway module, the vibration sent for real-time reception vibrating sensor and temperature data, collect and be uploaded to host computer by EPA, and receiving upper computer end and be sent to the configuration information of vibrating sensor, being handed down to the wireless vibration sensor of correspondence by wireless communication mode.
Preferably, the wireless communication mode between described vibrating sensor and gateway is ZigBee or wifi.
Further, described vibrating sensor also sets up power supply unit, and said supply unit built-in lithium battery, for directly powering for sensing unit；Said supply unit also sets up external electric supply socket, for external power supply for powering to lithium cell charging and for vibrating sensor.
As preferred version therein, described processor is enhancement mode 8051 or ARM or DSP.
Further, described vibrating sensor outside cladding aluminum shell.Described vibrating sensor base material is permanent magnet, and is provided with fixing circular hole.
Additionally, described gateway module, including antenna, processor, level switch module, mixed-media network modules mixed-media, network interface socket, serial ports socket, wherein,
Processor embedded RF transceiver, is connected with antenna, for communicating with vibrating sensor；
Mixed-media network modules mixed-media, is connected with processor and network interface socket, for providing a network interface for gateway module；
Level switch module, for carrying out the level conversion of processor, provides industrial communication interface for gateway module；
Serial ports socket, for providing industrial communication interface for gateway module.
Further, described gateway module is cladded with cuboid aluminium alloy waterproof case.
Further, the range of vibrating sensor, working method, high alarm setting are configured by described host computer with alarm level, sample rate, FFT average time parameter, monitor the time domain/frequency domain data of sensor in real time.
Wireless monitor system based on vibrating sensor provided by the present invention, has the advantage that
First: employing wireless network monitoring pattern builds vibration monitor system wireless, distributed, it is achieved while the monitoring in real time running plant equipment, saving cable wiring cost, maintainability is good, system flexibility is high；
Second: optional output time-domain/frequency-domain analysis data, save transformation process, substantially increase real-time and the efficiency of whole system；
3rd: vibrating sensor uses cylinder design, and bottom arranges fixing circular hole and uses permanent magnet material, makes easy for installation, applied widely, and frequency response range and real-time sampling rate are greatly improved.
Accompanying drawing explanation
Fig. 1 is present invention wireless monitor system based on vibrating sensor structural representation；
Fig. 2 is present invention wireless monitor system based on vibrating sensor vibrating sensor structural representation；
Fig. 3 is present invention wireless monitor system based on vibrating sensor vibrating sensor gateway module structural representation.
[critical piece symbol description]
1: vibrating sensor；2: wireless network；3: gateway module；4: EPA；5: host computer.
Detailed description of the invention
Below in conjunction with the accompanying drawings and the wireless monitor system based on vibrating sensor of the present invention is described in further detail by embodiment.
With reference to Fig. 1, wireless monitor system based on vibrating sensor, including host computer 5, gateway module 3 and at least one vibrating sensor 1, in base: host computer 5 is connected by EPA 4 with gateway module 3；Vibrating sensor 1 arranges DATA REASONING unit, for the online vibration data obtaining machinery and is sent to gateway module 3 by wireless transport module；Gateway module 3, the vibration data sent for real-time reception vibrating sensor 1, collect and pass through EPA 4 and be uploaded to host computer 5, and receive upper computer end and be sent to the configuration information of vibrating sensor, be handed down to the wireless vibration sensor of correspondence by wireless communication mode, described wireless transport module is preferably ZigBee or wifi wireless network 2 communication module.
With reference to Fig. 2, vibrating sensor includes sensing unit, and described sensing unit connects processor, described processor embedded RF transceiver by mating connector, is connected with antenna, for gateway module transceiving data；As preferably, described vibrating sensor also sets up power supply unit, and said supply unit built-in lithium battery, for directly powering for sensing unit.Wherein, said supply unit also sets up external electric supply socket, for external power supply for powering to lithium cell charging and for vibrating sensor.Vibrating sensor outside cladding aluminum shell, described vibrating sensor base material is permanent magnet, and is provided with fixing circular hole, it is easier to install, applied widely.Wireless vibration sensor outer housing material is cast aluminium, and cylindrically shaped, degree of protection reaches IP65.Bottom have three for fixing circular hole, and can be absorbed and fixed at by permanent magnet treat vibration survey mechanical surface.
Vibrating sensor is chosen as three axis vibration sensor, and interface circuit is a mating connector, with processor, vibrating sensor is carried out interface and is connected, and processor is enhancement mode 8051
CPU or DSP or ARM, embedded RF transceiver, it is connected with antenna, to radio network gateway module transceiving data；Direct current jack is connected with lithium battery, when there being connection external power source to power, can be disconnected by lithium battery, when without externally fed power supply, lithium battery gives whole sensor power.Achieved the hardware system of miniaturization by this design, be conducive to reducing volume and the setup cost of sensor, realize target's feature-extraction easily.
With reference to Fig. 3, radio network gateway module, being shaped as cuboid, material is aluminium alloy, uses waterproofing design.Including antenna, processor, level switch module, mixed-media network modules mixed-media, network interface socket, serial ports socket.Wherein, processor is enhancement mode 8051
CPU or DSP or ARM, embedded RF transceiver, it is connected with antenna, communicates with wireless vibration sensor；Mixed-media network modules mixed-media, is connected with processor and network interface socket, provides a network interface for radio network gateway module；Network interface socket is RJ45；Level switch module, is converted to 232/485 level by the Transistor-Transistor Logic level of processor；Serial ports socket is DB9, provides RS-232/485 interface for radio network gateway module.
Upper computer end, equipped with supporting monitoring of software, can carry out range, working method, high alarm setting are configured with alarm level, sample rate, FFT average time to wireless senser, it is possible to arranges the IP address of radio network gateway module.After setting relevant parameter, three axle time domain or frequency domain datas of corresponding wireless senser can be monitored in real time.
Generally, any equipment has multiple vibration source, such as bearing defect, imbalance and gear engagement etc., the vibration source brought in addition with design, the such as vibration that boring machine or press produce in course of normal operation.Traditional wireless vibration sensor has single shaft, twin shaft and three axles, but they provide only time-domain signal, time-based analysis meeting produces the complicated wave form of comprehensive all these vibration sources, before carrying out fft analysis, the information that it provides is difficult to distinguish, and majority piezoelectric transducer solution relies on outside FFT and calculates and analyze, host computer carries out frequency-domain analysis by specific software, this real-time not only making whole system and synchronicity have no possibility, and the work of major part additional designs is pushed outward towards equipment development business.And ours and wireless vibration sensor self just can provide the time-domain signal of three axles and corresponding frequency domain data, embedded fft analysis function, determine the concrete source of vibration skew in time, operate without on host computer, improve the work efficiency of host computer, ensure that the real-time of data, reduce the difficulty of programming, shorten the construction cycle.
Wireless vibration sensor before is cuboid mostly, for monitoring point with cambered surface on equipment, needs the most smooth contact area, very inconvenient during installation；We use cylinder design, need the contact area smooth with on equipment less, it is simple to install.
Typical data acquisition method includes simple piezoelectric transducer and the hand-held data collection instrument etc. being arranged on machine, with preferable complete detection compared with analyzing system scheme, there is multiple limitation in these methods, wireless vibration sensor is embedded on machine or in machine by we, passes through ZigBee
Wireless network mode real-time transmission data connects switch access industrial Ethernet and long-range host computer communication by netting twine to radio network gateway module, radio network gateway module, realizes real-time complete detection and analysis on host computer.
Wireless vibration sensor can realize the most able to programme, and parameter is as follows: can arrange range: 0-1g/5g/10g/20g according to actual needs；Single shaft/tri-axle real-time sampling rate can reach 20.48ksps, and the frequency response that the 5 smooth frequency ranges of kHz provide is suitable for many mechanical health condition detection application；Frequency domain processes and includes 512 points for each axle, most 255 the mean value computation functions of real number value FFT and FFT, it is possible to decrease noise variation, improves resolution；Programmable decimation filter, it is provided that 11 kinds of speed are arranged, it is also possible to three kinds of windowing processes are provided: rectangular window, Hanning window and laylight；Two kinds of grade high alarm settings of 6 frequency ranges can also be set, and digital power system voltage and temperature survey are provided.
Its workflow is as follows:
When there being externally fed, lithium cell charging both given by external power source, powered to whole system again；When without external power supply, lithium battery directly power.Pressing switch, electricly overall, sensor is started working, and is waiting the wireless RF data instruction that base station sends always, is working accordingly according to the order sent.
Host computer is connected by Ethernet with gateway module.During operation, upper computer software sends querying command to base station, base station is sent to be positioned over the wireless vibration sensor of monitoring field with wireless radio frequency mode after receiving, after vibrating sensor receives corresponding instruction, gateway module is wirelessly delivered in the vibration data gathered and processed packing, the wireless data received is delivered to host computer by network interface by gateway module again, and the packet sent to is resolved by upper computer software.
Claims (9)
1. wireless monitor system based on vibrating sensor, it is characterised in that: include host computer, gateway module and at least one vibrating sensor, wherein:
Described host computer is connected by EPA with gateway module；
Vibrating sensor, goes forward side by side line frequency domain analysis for the online vibration obtaining machinery and temperature data；Described vibrating sensor includes sensing unit and processor, and described sensing unit connects processor, described processor embedded RF transceiver by mating connector, is connected with antenna, for gateway module transceiving data；
Gateway module, the vibration sent for real-time reception vibrating sensor and temperature data, collect and be uploaded to host computer by EPA, and receiving upper computer end and be sent to the configuration information of vibrating sensor, being handed down to the wireless vibration sensor of correspondence by wireless communication mode.
Wireless monitor system based on vibrating sensor the most according to claim 1, it is characterised in that: the wireless communication mode between described vibrating sensor and gateway is ZigBee or wifi.
Wireless monitor system based on vibrating sensor the most according to claim 1, it is characterised in that: described vibrating sensor also sets up power supply unit, and said supply unit built-in lithium battery, for directly powering for sensing unit；Said supply unit also sets up external electric supply socket, for external power supply for powering to lithium cell charging and for vibrating sensor.
Wireless monitor system based on vibrating sensor the most according to claim 1, it is characterised in that: described processor is enhancement mode 8051 or ARM or DSP.
Wireless monitor system based on vibrating sensor the most according to claim 1, it is characterised in that: described vibrating sensor outside cladding aluminum shell.
Wireless monitor system based on vibrating sensor the most according to claim 1, it is characterised in that: described vibrating sensor base material is permanent magnet, and is provided with fixing circular hole.
Wireless monitor system based on vibrating sensor the most according to claim 1, it is characterised in that: described gateway module, including antenna, processor, level switch module, mixed-media network modules mixed-media, network interface socket, serial ports socket, wherein,
Processor embedded RF transceiver, is connected with antenna, for communicating with vibrating sensor；
Mixed-media network modules mixed-media, is connected with processor and network interface socket, for providing a network interface for gateway module；
Level switch module, for carrying out the level conversion of processor, provides industrial communication interface for gateway module；
Serial ports socket, for providing industrial communication interface for gateway module.
Wireless monitor system based on vibrating sensor the most according to claim 1, it is characterised in that: described gateway module is cladded with cuboid aluminium alloy waterproof case.
Wireless monitor system based on vibrating sensor the most according to claim 1, it is characterized in that: the range of vibrating sensor, working method, high alarm setting are configured with alarm level, sample rate, FFT average time parameter by described host computer, monitor the time domain/frequency domain data of sensor in real time.
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| CN2015101110802 | 2015-03-13 | ||
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| CN105974859A true CN105974859A (en) | 2016-09-28 |
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Cited By (2)
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| CN110879823A (en) * | 2019-11-29 | 2020-03-13 | 华北科技学院 | Wireless monitoring devices of mechanical vibration |
| US10743088B2 (en) | 2017-02-16 | 2020-08-11 | Watlow Electric Manufacturing Company | Compact modular wireless sensor |
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Cited By (3)
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Inventor after: Meng Yao Inventor after: Tan Xiufen Inventor after: Yin Tao Inventor before: Meng Xiangzhong Inventor before: Tan Xiufen Inventor before: Yin Tao |
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