CN117151681A - Performance early warning and intelligent overhauling method for continuous multistage ship lock operation equipment - Google Patents
Performance early warning and intelligent overhauling method for continuous multistage ship lock operation equipment Download PDFInfo
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Abstract
According to the method, various real-time data of a large number of ship lock equipment operation processes are accumulated through digitization of ship lock operation process information, operation equipment performance thresholds are obtained through calculation of standardized ship lock operation control process data and are used as basic references, historical performance data of the operation equipment are excavated and analyzed through preset performance trend analysis rules, potential equipment hazards are found out from performance change trends, early warning is provided for possible equipment faults, and performance early warning indexes are calculated according to an early warning algorithm.
Description
Technical Field
The invention relates to the technical field of ship lock control, in particular to a performance early warning and intelligent overhauling method for continuous multistage ship lock operation equipment.
Background
The ship lock is used as a water transportation channel for realizing the water conservancy junction ship lock, and the characteristics of various system components, various equipment forms, high comprehensiveness, strong technical performance and the like make the operation maintenance management of the ship lock, especially the equipment maintenance, the equipment inspection, the wheel repair and other maintenance decision making more complex and difficult. Particularly, for a continuous multistage ship lock, the facilities of a plurality of lock head ship lock devices are complicated and similar, but because of the difference of water level differences and working conditions among lock chambers of all stages, the operation parameters of the lock head equipment of the ship lock are different, the operation processes of the equipment are similar, and the performance trend analysis and fault positioning of the equipment become the key of the operation maintenance management of the equipment.
At present, the research of maintenance strategies and the establishment of operation maintenance periods for ship lock equipment at home and abroad are mainly based on the economy and reliability, and the performance grade evaluation, maintenance period establishment and maintenance decision formation of the ship lock equipment are considered from the aspects of economic life, risk and the like, so that the automatic acquisition of the performance of the ship lock equipment and the informatization processing of data are more and more important, the ship passing shipping requirements are continuously expanded along with the development of the economic society along the river, and the test of the passing capacity of the ship lock is also more and more increased, thereby providing higher requirements for the safety and the high efficiency of the operation maintenance management of the ship lock. The operation and maintenance of ship lock equipment basically depend on the compensatory treatment of the equipment faults which occur, or the periodical planning of the navigation stoppage maintenance and the wheel repair are periodical evaluation based on results and passive adjustment maintenance based on faults, in order to change the mode of the maintenance management which is always passive and delayed, a management method suitable for continuous multistage ship lock equipment facility performance trend and fault early warning analysis and intelligent maintenance needs to be researched, the acquisition and analysis of equipment performance are utilized, the performance change trend is controlled, the early warning is carried out on the faults which can occur, the active and targeted maintenance work can be reasonably arranged before the faults occur, and a scientific spare part storage strategy is formulated, so that hidden danger is eliminated in advance, and the occurrence of the faults is prevented.
Disclosure of Invention
The invention aims to solve the defects that in the prior art, the running management and maintenance process of the multistage ship lock overhauls the faults, so that overhauling work is always in a passive and delayed state and cannot be prevented before the faults occur, and the pertinence and the accuracy of the fault investigation are not outstanding.
In order to solve the technical problems, the invention adopts the following technical scheme:
step 1: through extensive collection of the historical performance data of the ship lock equipment operation, a large amount of the performance data of the ship lock equipment is obtained, and the method comprises the following steps: building a training model based on the historical data, analyzing the performance trend of the ship lock operation equipment by mining, performing model training by using standardized ship lock operation control process equipment operation data, calculating an operation equipment performance threshold value, and refining the ship lock equipment operation standard data;
step 2: through preset performance trend analysis rules, performance trend calculation formulas, threshold setting rules, corresponding relation between performance and set fault levels, equipment hidden danger is found out from the trend of the performance change of operation equipment, early warning is provided for equipment faults which possibly occur, and equipment performance early warning indexes and equipment operation efficiency evaluation factors are calculated according to an early warning algorithm;
Step 3: and judging the performance early warning and judging the early warning grade according to the performance early warning rule if the data mutation and the mutation frequency thereof are found to exceed the preset margin, and carrying out early warning prompt and coping strategies of the corresponding grade.
Further, the historical data of the ship lock operation process mainly comprises operation data of a ship lock control system, ship lock facility state conversion process data, ship lock water level conversion process data and operation space data, wherein the data collected by the ship lock control system are mainly ship lock operation state signals in a PLC system. According to the collection of the operation history data of the ship lock equipment facilities, the training model construction of the same parameters but not shared is carried out in a classified manner, a training set P is constructed based on the history data,P x is the x-th sample in training set P, < >> Is sample P x The acquired device performance index at time T, T being the time series length, < >>And running the data sequence for the first lock device. Preprocessing samples in training set and utilizing aggregationClass algorithms are trained.
Further, the ship lock operation state signal in the ship lock PLC control system mainly comprises digital quantity signals, analog quantity signals, character type, time type and floating point type data according to the data type, equipment operation data and alarm information are obtained according to the ship lock equipment operation period, and alarm data in a plurality of data formats which can represent whether faults occur are obtained according to each piece of alarm information. Creating an alarm record, recording each alarm data according to the acquisition time of the alarm data and the time sequence, obtaining the alarm record, judging whether two pieces of alarm data with the same alarm type exist in the pieces of alarm data with the same acquisition time and the same value, if the two pieces of alarm data with the same alarm type exist in the pieces of alarm data with the same alarm type and the same value, accumulating the record, taking the accumulated times as a basic basis for judging the performance of equipment, and covering the alarm data with the previous acquisition time by the alarm data with the later acquisition time to obtain the residual data; recording a plurality of pieces of residual data with the same alarm type according to the sequence of the acquisition time to obtain an alarm sub-record, and extracting equipment information corresponding to the alarm point from the alarm record according to the corresponding relation between the plurality of pieces of alarm data and the plurality of acquisition times.
Further, in step 1, the method specifically includes the following steps:
step 1-1: acquiring equipment operation data and alarm information according to a ship lock equipment operation period, and acquiring alarm data in a plurality of data formats capable of representing whether faults occur according to each piece of alarm information;
step 1-2: creating an alarm record, recording each alarm data according to the acquisition time of the alarm data and the time sequence, classifying the equipment operation data in K clusters, and outputting a reconstructed standard data sequence;
step 1-3: acquiring the alarm record, judging whether two pieces of alarm data with the same alarm type and the same value exist in the pieces of alarm data with the same alarm type, if the two pieces of alarm data with the same alarm type and the same value exist in the pieces of alarm data with the same alarm type and the same value, accumulating the record, taking the accumulated times as a basic basis for judging the performance of equipment, and covering the alarm data with the previous acquisition time by the alarm data with the later acquisition time to obtain the residual data;
step 1-4: recording a plurality of pieces of residual data with the same alarm type according to the sequence of the acquisition time to obtain an alarm sub-record, and extracting equipment information and equipment position information corresponding to the alarm point from the alarm record according to the corresponding relation between the plurality of pieces of alarm data and the plurality of acquisition times.
Furthermore, the acquired data in the step 1 are divided into digital quantity signals, analog quantity signals, character type, time type and floating point type data according to the data types, the acquisition scheme mainly comprises the steps of expanding a remote station in a ship lock electrical control PLC control cabinet, adding a digital quantity and analog quantity output module, outputting signals related to an electrical control equipment monitoring system in a ship lock operation control system to the electrical control cabinet in a passive node and analog signal mode, and acquiring, processing and transmitting the monitoring signals to an acquisition computer by a PLC control equipment configured in the electrical control cabinet. The signal of the newly-added digital quantity output module directly outputs the ship lock operation signal to the newly-added electrical control cabinet through coding, and is connected to an electrical control equipment acquisition system after electrical isolation. Each newly-added monitoring acquisition station is powered by a single power supply, and a UPS power supply is configured in the electrical control cabinet. The isolation acquisition of the output signals of the original PLC control system is realized on the premise of ensuring the reliability of the power supply;
the equipment operation data obtained by the acquisition scheme is matched and compared with the equipment operation data of the design primary standardized ship lock operation control process to obtain the equipment performance threshold value, so that the ship lock equipment operation standard data is extracted.
Further, in step 2, according to the real-time data of the operation of the equipment collected by the collection system, the real-time data is input into the training model to obtain the detection data of the reconstructed output sequence, the model calculates the performance early warning index S of the equipment, and the established performance early warning index of the ship lock equipment is obtained by the method of the equipmentThe performance out-of-limit rate, the performance importance and the equipment importance are comprehensively calculated, and the index is used as a quantization standard for early warning classification. Let the performance pre-warning index be S and the performance threshold rate be T i The performance importance is N, the equipment importance is K 1 The adjustment coefficient is K 2 The calculation formula is as follows:
S＝(1+T i )*N*K 1 *K 2
t in i And according to the deviation between the performance threshold value and the actual value, the calculation is carried out: t (T) i ＝t 1 /t 2 *100%. Wherein K is 2 The parameters set by people are mainly analyzed according to historical experience or historical data and evaluated and analyzed by an expert system. In the early warning calculation process, higher early warning values are given to gate valve switch final position signals, gate closure signals, upstream and downstream control equipment and process fault alarm signals, important index data of ship lock operation control instruction signals and repeated fault signals, accurate positioning is carried out, and equipment inspection and operation attention (monitoring intensity) is increased. Along with the dynamic change of actual conditions, the early warning level of the index can be flexibly lifted, mainly through K 2 And (5) adjusting. Importance of the device K 1 According to the classification method of continuous multistage ship lock operation equipment, different values are taken, and the main classification method is as follows:
(1) The method comprises the steps that host equipment which affects navigation of a ship lock in a navigation mode is divided into class A equipment, wherein the class A equipment comprises a lock valve, a gate valve hoist, an electrical control system, a power transformation and distribution system, an image monitoring system, a fire alarm system and a floating access door;
(2) Dividing operation equipment which has an obstacle effect on navigation of a ship lock into B-class equipment, wherein the B-class equipment comprises a lighting system, a broadcasting system, an anti-collision warning device, an access control system, a floating type dolphin, a drainage system, an accident access door and an air conditioning system;
(3) The operation equipment which does not generate the influence of navigation stoppage or navigation obstruction on the navigation of the ship lock is divided into C-type equipment, wherein the C-type equipment comprises oil liquid filtering equipment, electric lubrication equipment, sewage treatment equipment, an electronic inspection system, a diagnostic analyzer, a verification instrument and office equipment. The performance early warning index S is obtained through the algorithm, and corresponding early warning values are given to different early warning indexes. And setting a closed section with an early warning value range of 0-1, wherein the magnitude of the numerical value reflects the severity of early warning and is used as a basis for quantitatively evaluating the performance of the ship lock equipment.
Further, in step 3, the ship lock device performance pre-warning rule is: and setting a closed interval with the early warning value range of 0-1, wherein the magnitude of the numerical value reflects the severity of early warning, 0 indicates that the fault is unlikely to occur, and 1 indicates that the fault is necessarily occurring. According to the performance early warning classification of ship lock equipment, different inspection and equipment maintenance strategies are adopted for the performance early warning of different levels, refinement analysis is performed, operation control modes with different rules and equipment fixed inspection and maintenance plans are generated through an intelligent operation platform, corresponding equipment operation control modes and fixed inspection and maintenance plans are respectively defined aiming at 'fault', 'defect', 'hidden danger' and 'problem' early warning, and the method specifically comprises the following steps:
Step 3-1: regarding the early warning value between 0 and 0.35, the performance trend of the equipment is considered to be an unobvious decline trend, the level of the equipment is classified as a problem, and the condition that the performance trend of the equipment is unobvious decline or unstable is usually considered, the operation of the ship lock is not influenced negatively temporarily, and the problem cannot be determined;
step 3-2: for the early warning value between 0.35 and 0.55, the severity is considered to be lower, the level of the early warning value is divided into hidden danger, the performance is usually reduced due to the degradation, aging and other reasons of equipment, the trend is obvious, and if the early warning value is not processed for a long time, the operation efficiency of the equipment is reduced or even the operation is interrupted;
step 3-3: for early warning values between 0.55 and 0.75, the equipment is considered to have middle and low risk of failure, the grade is classified as 'defect', and if the equipment is not processed, the operation efficiency of the ship lock equipment can be affected, but serious accidents are not caused. For the early warning, generating a corresponding fixed inspection tour inspection and overhaul plan;
step 3-4: for early warning values between 0.75-1, the equipment can be considered to have high risk or be in fault, the level of the equipment is divided into 'fault', and relevant measures are immediately taken to solve the fault. For such early warning, a regular inspection tour inspection and maintenance plan is generated for coping with.
In step 3-1, the equipment operation control mode and the fixed inspection tour inspection and overhaul plan include: and (5) adjusting the inspection period. When a fault occurs, the system gives an alarm prompt, and meanwhile, the running system enters a protective running state, and only the running is completed. The fault must be removed after the operation is finished, otherwise the system does not allow the next operation.
In step 3-2, the equipment operation control mode and the fixed inspection tour inspection and overhaul plan include: and (3) adjusting the inspection period and increasing the acquisition of auxiliary performance values. When a fault occurs, the system gives an alarm prompt. Meanwhile, the system part related to the fault stops running, and the part can normally run only after the fault is removed.
In step 3-3, the equipment operation control mode and the fixed inspection tour inspection and overhaul plan comprise: the inspection period is adjusted, the inspection plan is increased, and the auxiliary performance value acquisition is increased, so that the performance change condition can be more accurately positioned and tracked in real time. When a fault occurs, the system gives an alarm prompt. Meanwhile, the running system equipment stops running, if the gate valve A type equipment is in the middle position, the system stops running after critical equipment such as a gate valve is closed in an emergency, and the system can normally run after the fault is removed.
In step 3-4, the equipment operation control mode and the fixed inspection tour inspection and overhaul plan comprise: the attention of fault equipment is increased, the inspection period is adjusted, the inspection plan is increased, and the acquisition of auxiliary performance values is increased. When a fault occurs, the system gives an alarm prompt, and meanwhile, the whole system enters forbidden operation. And entering an emergency operation state if the system equipment is running, and stopping and clearing the central control system running program step.
Further, in the third step, the coping strategy further includes: and respectively making corresponding equipment spare part storage strategies aiming at the early warning of faults, defects, hidden dangers and problems, and particularly as follows.
(1) For the equipment performance early warning of the 'fault' level, the operation control mode has great influence on navigation of the ship lock, and the reserve quantity of spare parts is determined according to the working condition, the installed quantity and the service life analysis of the spare parts. No backorder is allowed and a quantitative storage strategy is adopted, namely, a certain reserve is necessary in the stock, and the backorder should be ordered immediately after spare parts are consumed until the reserve of the stock.
(2) For the equipment performance early warning of the defect level, the operation control mode has great influence on navigation of the ship lock, the maximum inventory and the minimum inventory are determined according to the installed quantity, the loss degree and the average service life, the inventory is reserved according to the maximum inventory, and the strategy of ensuring the minimum inventory and replenishing the inventory to the maximum inventory is adopted. Adopting quantitative storage strategy, namely ordering goods as storage supplement at intervals of 12 months, supplementing to the maximum stock quantity and the maximum stock quota Q max =m×t×k, lowest reserve quota Q min ＝M×T d X K, where M is the average spare part month consumption, m=m/M T M is the installed number of equipment spare parts, M T The average service life of spare parts is determined by combining the design service life of equipment and the performance early warning value; t is the purchasing period, T d Is the supply cycle, K is the reserve factor of the spare part.
(3) For the equipment performance early warning of the hidden danger level, the operation control mode of the equipment performance early warning can not directly influence navigation, and a regular quantitative storage strategy is adopted, namely a certain reserve quantity is required to be reserved in the stock, and the reserve quantity calculation formula is adopted: q (Q) const M×t×k, where M is the average spare part month consumption, m=m/M T M is the installed number of equipment spare parts, M T The average service life of spare parts is determined by combining the design service life of equipment and the performance early warning value; t is the purchasing period, and K is the reserve coefficient of the spare part.
(4) For the equipment performance early warning of the 'problem' level, the operation control mode of the equipment performance early warning can not directly influence navigation, and a regular quantitative storage strategy is adopted, namely, a certain reserve amount is reserved in the stock, and the reserve amount calculation formula is adopted: q (Q) const M×t×k, where M is the average spare part month consumption, m=m/M T M is the installed number of equipment spare parts, M T The average service life of spare parts is determined by combining the design service life of equipment and the performance early warning value; t is the purchasing period, K Is a reserve coefficient for spare parts.
Compared with the prior art, the invention has the following technical effects:
1) According to the invention, through widely collecting historical data and alarm information of continuous multistage ship lock operation equipment, a control system data collection scheme and equipment performance judgment basis which are suitable for the continuous multistage ship lock operation process are obtained, so that the ship lock operation process is digitized into information in a specific data format, and a foundation is laid for comprehensively grasping the equipment performance condition;
2) On the basis of collecting and processing data and fault information of continuous multistage ship lock operation equipment, equipment hidden danger is found out from the trend of the performance change of the operation equipment, early warning is provided for equipment faults which possibly occur, and equipment performance early warning indexes are calculated according to an early warning algorithm, so that intelligent management of the continuous multistage ship lock operation equipment is realized;
3) The performance early warning rule of the continuous multistage ship lock operation equipment is quantized, so that the equipment inspection maintenance decision process is more intelligent, scientific and reasonable, and the integrated management and control process of the continuous multistage ship lock operation management process is promoted.
Drawings
The invention is further illustrated by the following examples in conjunction with the accompanying drawings:
FIG. 1 is a schematic diagram of a data acquisition scheme of a continuous multi-stage ship lock operation process according to the present invention;
FIG. 2 is a flow chart of the continuous multi-stage lock device operation data and fault information processing of the present invention;
FIG. 3 is a flow chart of the performance early warning analysis of the continuous multi-stage ship lock operation process equipment of the invention;
fig. 4 is a schematic diagram of a process data collection flow of a ship lock operation device according to an embodiment of the present invention.
Fig. 5 is a schematic diagram of an acquisition system according to an embodiment of the invention.
Detailed Description
A performance early warning and intelligent overhauling method for continuous multistage ship lock operation equipment comprises the following steps:
step one: acquiring a large amount of ship lock equipment performance data through the extensive collection of the ship lock equipment operation history performance data, constructing a training model based on the history data, analyzing the performance trend of the operation equipment through excavation, performing model training by using standardized ship lock operation control process equipment operation data, calculating an operation equipment performance threshold value, and refining equipment operation standard data;
the ship lock operation process historical data mainly comprises ship lock control system operation data, ship lock facility state conversion process data, ship lock water level conversion process data and operation space data, wherein the data collected by the ship lock control system is mainly a ship lock operation state signal in the PLC system. A training set P is constructed based on the history data, P x Is the x-th sample in training set P, < >> Is sample P x The acquired device performance index at time T, T being the time series length, < >>And running the data sequence for the first lock device.
The ship lock operation state signals in the ship lock control system mainly comprise digital quantity signals, analog quantity signals, character type, time type and floating point type data according to the data type, equipment operation data and alarm information are obtained according to the operation period of ship lock equipment, and alarm data in a plurality of data formats which can represent whether faults occur are obtained according to each piece of alarm information. Creating an alarm record, recording each alarm data according to the acquisition time of the alarm data and the time sequence, obtaining the alarm record, judging whether two pieces of alarm data with the same alarm type exist in the pieces of alarm data with the same acquisition time and the same value, if the two pieces of alarm data with the same alarm type exist in the pieces of alarm data with the same alarm type and the same value, accumulating the record, taking the accumulated times as a basic basis for judging the performance of equipment, and covering the alarm data with the previous acquisition time by the alarm data with the later acquisition time to obtain the residual data; and recording a plurality of pieces of residual data with the same alarm type according to the sequence of the acquisition time to obtain an alarm sub-record. And extracting equipment information corresponding to the alarm point from the alarm record according to the corresponding relation between the alarm data and the acquisition times.
The specific acquisition scheme mainly expands a remote station through a ship lock electrical control PLC control cabinet, increases a digital quantity and analog quantity output module, outputs signals related to an electrical control equipment monitoring system in a ship lock operation control system to the electrical control cabinet in a passive node and analog signal mode, and performs signal acquisition and processing on the monitoring signals through PLC control equipment configured in the electrical control cabinet and transmits the monitoring signals to an acquisition computer. The digital output module is added in the PLC control cabinet of the existing lock control system local substation, an electrical control cabinet is added under each local machine room control room of the multistage lock, a power protection switch is arranged in the electrical control cabinet, and a signal acquisition unit (comprising a PLC main CPU, a rack, a power module, a digital input module), a network switch and the like are arranged. The signal of the newly-added digital quantity output module directly outputs the ship lock operation signal to the newly-added electrical control cabinet through coding, and is connected to an electrical control equipment acquisition system after electrical isolation. Each newly-added monitoring acquisition station is powered by a single power supply, and a UPS power supply is configured in the electrical control cabinet. The isolation acquisition of the output signals of the original PLC control system is realized on the premise of ensuring the reliability of the power supply.
The equipment operation data obtained by the acquisition scheme is matched and compared with the equipment operation data of the design primary standardized ship lock operation control process to obtain the equipment performance threshold value, so that the ship lock equipment operation standard data is extracted.
As shown in FIG. 5, the floating point data acquisition system for each sensing detection in the ship lock operation system mainly comprises a communication module, a data acquisition module, a service display interface module and a database interface module. The communication module is mainly responsible for receiving data frames uploaded by the sensor or the intelligent terminal and transmitting control command data frames and configuration command data frames to the intelligent terminal by the data center, and reliable transmission of data is ensured by mainly utilizing Socket communication technology. The service display interface module mainly provides a plurality of service calling interfaces, is connected with the Web server, intuitively and clearly displays the result processed by the data processing module on the man-machine interface, and provides a service data query function for users. And meanwhile, the module receives a control command or a configuration command issued by a user, encapsulates the related command into a data frame specified by a protocol and issues the data frame to the sensor or the intelligent device through the communication module. The database interface module is mainly responsible for the read-write operation of the database. The data acquisition module is the core of the acquisition system, and the identification and analysis of the protocol are the main functions of the module. The method is mainly responsible for translating a communication protocol, analyzing a data frame actively uploaded by equipment or a data frame responding to an issued command, and storing an analysis result into a database or displaying data on a human-computer interface through a service display interface module.
Step two: finding out equipment hidden danger from the trend of the performance change of the operation equipment according to a preset performance trend analysis rule, a performance trend calculation formula, a threshold setting rule and a rule of the corresponding relation between the performance and the set fault level, providing early warning for the possible equipment faults, and calculating equipment performance early warning indexes and equipment operation efficiency evaluation factors according to an early warning algorithm;
the established ship lock equipment performance early warning index is obtained by comprehensively calculating the performance out-of-limit rate, the performance importance and the equipment importance, and the index is used as a quantization standard of early warning grading. Let the performance pre-warning index be S and the performance threshold rate be T i The performance importance is N, the equipment importance is K 1 The adjustment coefficient is K 2 The calculation formula is as follows:
S＝(1+T i )*N*K 1 *K 2
t in i And according to the deviation between the performance threshold value and the actual value, the calculation is carried out: t (T) i ＝t 1 /t 2 *100%. Wherein K is 2 The parameters set by people are mainly analyzed according to historical experience or historical data and evaluated and analyzed by an expert system. In the early warning calculation process, higher early warning values are given to gate valve switch final position signals, gate closure signals, upstream and downstream control equipment and process fault alarm signals, important index data of ship lock operation control instruction signals and repeated fault signals, accurate positioning is carried out, and equipment inspection and operation attention (monitoring intensity) is increased. Along with the dynamic change of the actual situation, the early warning level of the index can be flexibly lifted, and the early warning level is mainly adjusted through K2. Importance of the device K 1 According to a continuous multistage ship lock operation equipment classification method, different values are taken, and host equipment which has a navigation stopping effect on ship lock navigation is divided into class A equipment, wherein the class A equipment comprises a lock valve, a gate valve hoist, an electrical control system, a power transformation and distribution system, an image monitoring system, a fire alarm system and a floating access door; dividing operation equipment which has an obstacle effect on navigation of a ship lock into B-class equipment, wherein the B-class equipment comprises a lighting system, a broadcasting system, an anti-collision device, an access control system, a floating dolphin, a drainage system, an accident access door and an air conditioning system; the operation equipment which does not generate the influence of navigation stoppage or navigation obstruction on the navigation of the ship lock is divided into C-type equipment, wherein the C-type equipment comprises oil liquid filtering equipment, electric lubrication equipment, sewage treatment equipment, an electronic inspection system, a diagnostic analyzer, a verification instrument and office equipment. Along with the dynamic change of actual conditions, the early warning level of the index can be flexibly lifted, mainly through K 2 And (5) adjusting.
The performance early warning index S is obtained through the algorithm, and corresponding early warning values are given to different early warning indexes. And setting a closed section with an early warning value range of 0-1, wherein the magnitude of the numerical value reflects the severity of early warning and is used as a basis for quantitatively evaluating the performance of the ship lock equipment.
Step three: and judging the performance early warning and judging the early warning grade according to the performance early warning rule if the data mutation and the mutation frequency thereof are found to exceed the preset margin, and carrying out early warning prompt and coping strategies of the corresponding grade.
The ship lock equipment performance early warning rule is as follows: and setting a closed interval with the early warning value range of 0-1, wherein the magnitude of the numerical value reflects the severity of early warning, 0 indicates that the fault is unlikely to occur, and 1 indicates that the fault is necessarily occurring. For the early warning value between 0 and 0.35, the performance trend of the equipment is considered to show no obvious descending trend, and the grade of the equipment is classified as a problem; for early warning values between 0.35 and 0.55, the severity is considered to be low, and the level is classified as hidden danger; for early warning values between 0.55 and 0.75, the equipment is considered to have middle and low risk of failure, and the grade of the equipment is classified as 'defect'; for early warning values between 0.75-1, the device may be considered to be at high risk or will fail, and its level is classified as "failure". According to the performance early warning classification of the ship lock equipment, different inspection and equipment maintenance strategies are adopted for the performance early warning of different levels, refinement analysis is carried out, operation control modes of different rules and equipment fixed inspection and maintenance plans are generated through an intelligent operation platform, and aiming at 'faults', 'defects', 'hidden dangers' and 'problems' early warning, the equipment operation control modes of rules 1 to 4 and the fixed inspection and maintenance plans are respectively defined, and the method is specifically divided as follows.
(1) The equipment operation control mode conforming to rule 1 and the inspection and maintenance plan: for the early warning that the analysis result is "fault", the method generally means that a great hidden danger exists, and related measures should be immediately taken to solve the fault. For such early warning, generating a regular inspection tour inspection and overhaul plan conforming to rule 1 for treatment includes: the attention of fault equipment is increased, the inspection period is adjusted, the inspection plan is increased, the acquisition of auxiliary performance values is increased, and the like. When a fault occurs, the system gives an alarm prompt, and meanwhile, the whole system enters forbidden operation. And entering an emergency operation state if the system equipment is running, and stopping and clearing the central control system running program step.
(2) And (3) a device operation control mode conforming to rule 2 and a fixed inspection tour inspection and overhaul plan: for the early warning that the analysis result is 'defect', namely the problem that the equipment really exists is found, if the equipment is not processed, the operation efficiency of the ship lock equipment can be affected, but serious accidents are not caused. For such early warning, generating a regular inspection tour inspection and inspection plan conforming to rule 2, comprising: the inspection period is adjusted, the inspection plan is increased, the auxiliary performance value acquisition is increased, and the like, so that the performance change condition can be more accurately positioned and tracked in real time. When a fault occurs, the system gives an alarm prompt. Meanwhile, the running system equipment stops running, if key equipment such as a gate valve is positioned in the middle position, the system stops running after the key equipment such as the gate valve is closed in an emergency, and the system can normally run after the fault is removed.
(3) And (3) a device operation control mode conforming to rule 3 and a fixed inspection tour inspection and overhaul plan: for the early warning that the analysis result is the hidden trouble, the performance is reduced due to the reasons of equipment degradation, aging and the like, the trend is obvious, and if the equipment is not processed for a long time, the operation efficiency of the equipment is reduced and even the operation is interrupted. For such early warning, generating a regular inspection tour inspection and inspection plan conforming to rule 3 includes: adjusting the inspection period, increasing the collection of auxiliary performance values, and the like. When a fault occurs, the system gives an alarm prompt. Meanwhile, the system part related to the fault stops running, and the part can normally run only after the fault is removed.
(4) And (3) a device operation control mode conforming to rule 4 and a fixed inspection tour inspection and overhaul plan: for the early warning that the analysis result is a problem, the performance trend of the equipment is not obviously reduced or unstable, the operation of the ship lock is not influenced negatively temporarily, and the problem cannot be determined. For such early warning, a regular inspection tour inspection and inspection plan conforming to rule 4 should be generated, including: and (5) adjusting the inspection period and the like. When a fault occurs, the system gives an alarm prompt, and meanwhile, the running system enters a protective running state, and only the running is completed. The fault must be removed after the operation is finished, otherwise the system does not allow the next operation.
According to the acquisition of the operation history data of the ship lock equipment, the same training model construction without sharing parameters is carried out in a classified manner, samples in a training set are preprocessed and trained by using a clustering algorithm, K clusters of the data are classified, a reconstructed standard data sequence is output, according to the equipment operation real-time data acquired by an acquisition system, the reconstructed output sequence detection data is obtained by inputting the training model, the equipment performance early warning index S is calculated by the model, corresponding early warning values are given out by combining different early warning indexes, and different inspection and equipment maintenance strategies are generated.
The coping strategy further comprises: and respectively making corresponding equipment spare part storage strategies aiming at the early warning of faults, defects, hidden dangers and problems, and particularly as follows.
(1) For the equipment performance early warning of the 'fault' level, the operation control mode has great influence on navigation of the ship lock, and the reserve quantity of spare parts is determined according to the working condition, the installed quantity and the service life analysis of the spare parts. No backorder is allowed and a quantitative storage strategy is adopted, namely, a certain reserve is necessary in the stock, and the backorder should be ordered immediately after spare parts are consumed until the reserve of the stock.
(2) For the equipment performance early warning of the defect level, the operation control mode has great influence on navigation of the ship lock, the maximum inventory and the minimum inventory are determined according to the installed quantity, the loss degree and the average service life, the inventory is reserved according to the maximum inventory, and the strategy of ensuring the minimum inventory and replenishing the inventory to the maximum inventory is adopted. Adopting quantitative storage strategy, namely ordering goods as storage supplement at intervals of 12 months, supplementing to the maximum stock quantity and the maximum stock quota Q max =m×t×k, lowest reserve quota Q min ＝M×T d X K, where M is the average spare part month consumption, m=m/M T M is the installed number of equipment spare parts, M T The average service life of spare parts is determined by combining the design service life of equipment and the performance early warning value; t is the purchasing period, T d Is the supply cycle, K is the reserve factor of the spare part.
(3) For the equipment performance early warning of the hidden danger level, the operation control mode of the equipment performance early warning can not directly influence navigation, and a regular quantitative storage strategy is adopted, namely a certain reserve quantity is required to be reserved in the stock, and the reserve quantity calculation formula is adopted: q (Q) const M×t×k, where M is the average spare part month consumption, m=m/M T M is the installed number of equipment spare parts, M T The average service life of spare parts is determined by combining the design service life of equipment and the performance early warning value; t is the purchasing period, and K is the reserve coefficient of the spare part.
(4) For the equipment performance early warning of the 'problem' level, the operation control mode of the equipment performance early warning can not directly influence navigation, and a regular quantitative storage strategy is adopted, namely, a certain reserve amount is reserved in the stock, and the reserve amount calculation formula is adopted: q (Q) const M×t×k, where M is the average spare part month consumption, m=m/M T M is the installed number of equipment spare parts, M T The average service life of spare parts is determined by combining the design service life of equipment and the performance early warning value; t is the purchasing period, and K is the reserve coefficient of the spare part.
Claims (7)
1. A performance early warning and intelligent overhauling method for continuous multistage ship lock operation equipment is characterized by comprising the following steps:
step 1: acquiring a large amount of ship lock equipment performance data through the extensive collection of the ship lock equipment operation history performance data, constructing a training model based on the history data, analyzing the performance trend of the operation equipment through excavation, performing model training by using standardized ship lock operation control process equipment operation data, calculating an operation equipment performance threshold value, and refining the ship lock equipment operation standard data;
step 2: finding out equipment hidden danger from the trend of the performance change of the operation equipment according to a preset performance trend analysis rule, a performance trend calculation formula, a threshold setting rule and a rule of the corresponding relation between the performance and the set fault level, providing early warning for the possible equipment faults, and calculating equipment performance early warning indexes and equipment operation efficiency evaluation factors according to an early warning algorithm;
Step 3: and judging the performance early warning and judging the early warning grade according to the performance early warning rule if the data mutation and the mutation frequency thereof are found to exceed the preset margin, and carrying out early warning prompt and coping strategies of the corresponding grade.
2. The method of claim 1, wherein in step 1, the ship lock operation history data mainly includes ship lock control system operation data, ship lock facility state conversion process data, ship lock water level conversion process data, and operation space data, wherein the ship lock control system takes in the ship lockThe data of the set is mainly a ship lock running state signal in the PLC system, training model construction with the same parameters but not shared is carried out according to the collection of the ship lock equipment facility running history data in a classified manner, a training set P is constructed based on the history data,P x is the x-th sample in training set P, < >> Is sample P x The acquired device performance index at time T, T being the time series length, < >>And running a data sequence for the first lock equipment, preprocessing samples in the training set and training by using a clustering algorithm.
3. The method according to claim 1, characterized in that in step 1, it comprises in particular the following steps:
step 1-1: acquiring equipment operation data and alarm information according to a ship lock equipment operation period, and acquiring alarm data in a plurality of data formats capable of representing whether faults occur according to each piece of alarm information;
Step 1-2: creating an alarm record, recording each alarm data according to the acquisition time of the alarm data and the time sequence, classifying the equipment operation data in K clusters, and outputting a reconstructed standard data sequence;
step 1-3: acquiring the alarm record, judging whether two pieces of alarm data with the same alarm type and the same value exist in the pieces of alarm data with the same alarm type, if the two pieces of alarm data with the same alarm type and the same value exist in the pieces of alarm data with the same alarm type and the same value, accumulating the record, taking the accumulated times as a basic basis for judging the performance of equipment, and covering the alarm data with the previous acquisition time by the alarm data with the later acquisition time to obtain the residual data;
step 1-4: recording a plurality of pieces of residual data with the same alarm type according to the sequence of the acquisition time to obtain an alarm sub-record, and extracting equipment information and equipment position information corresponding to the alarm point from the alarm record according to the corresponding relation between the plurality of pieces of alarm data and the plurality of acquisition times.
4. The method of claim 1, wherein the collected data in step 1 is divided into digital quantity signals, analog quantity signals, character type, time type and floating point type data according to the data types, the collection scheme mainly comprises the steps of expanding a remote station in a ship lock electrical control PLC control cabinet, adding digital quantity and analog quantity output modules, outputting signals related to an electrical control equipment monitoring system in the ship lock operation control system to the electrical control cabinet in a passive node and analog signal mode, carrying out signal collection and processing on the monitoring signals by a PLC control equipment configured in the electrical control cabinet, transmitting the signals to a collection computer, directly outputting the ship lock operation signals to a newly-added electrical control cabinet through encoding by the newly-added digital quantity output module signals, and accessing the electrical control equipment collection system after electrical isolation, wherein each newly-added monitoring collection station is powered by a single power supply, and a UPS power supply is configured in the electrical control cabinet, so that isolation collection of the output signals of the original PLC control system is realized on the premise of guaranteeing the reliability of the power supply;
The equipment operation data obtained by the acquisition scheme is matched and compared with the equipment operation data of the design primary standardized ship lock operation control process to obtain the equipment performance threshold value, so that the ship lock equipment operation standard data is extracted.
5. The method according to claim 1, wherein in step 2, based on real-time data of the operation of the device collected by the collection system, the device is input into a training model to obtain reconstructed output sequence detection data, and the device performance pre-warning means is calculated by the modelThe standard S is the established performance early warning index of the ship lock equipment, which is obtained by comprehensively calculating the performance out-of-limit rate, the performance importance and the equipment importance, and is used as the quantification standard of early warning grading, and the performance early warning index is S and the performance out-of-limit rate is T i The performance importance is N, the equipment importance is K 1 The adjustment coefficient is K 2 The calculation formula is as follows:
S＝(1+T i )*N*K 1 *K 2
t in i And according to the deviation between the performance threshold value and the actual value, the calculation is carried out: t (T) i ＝t 1 /t 2 *100, where K 2 The method is characterized in that parameters set manually are mainly analyzed according to historical experience or historical data and expert system evaluation, and in the early warning calculation process, higher early warning values are given to important index data of gate valve opening and closing final position signals, gate closure signals, upstream and downstream control equipment and process fault alarm signals and ship lock operation control instruction signals and repeated fault signals, so that accurate positioning is performed, and equipment inspection and operation attention is increased; along with the dynamic change of actual conditions, the early warning level of the index can be flexibly lifted, mainly through K 2 Adjusting the importance K of the equipment 1 According to the classification method of continuous multistage ship lock operation equipment, different values are taken, and the main classification method is as follows:
(1) The method comprises the steps that host equipment which affects navigation of a ship lock in a navigation mode is divided into class A equipment, wherein the class A equipment comprises a lock valve, a gate valve hoist, an electrical control system, a power transformation and distribution system, an image monitoring system, a fire alarm system and a floating access door;
(2) Dividing operation equipment which has an obstacle effect on navigation of a ship lock into B-class equipment, wherein the B-class equipment comprises a lighting system, a broadcasting system, an anti-collision warning device, an access control system, a floating type dolphin, a drainage system, an accident access door and an air conditioning system;
(3) The operation equipment which does not generate the influence of navigation stoppage or navigation obstruction on the ship lock is divided into C-type equipment, wherein the C-type equipment comprises oil filtering equipment, electric lubrication equipment, sewage treatment equipment, an electronic inspection system, a diagnostic analyzer, a checking instrument and office equipment, the performance early warning index S is obtained through the algorithm, corresponding early warning values are given for different early warning indexes, a closed zone with the early warning value range of 0-1 is set, the severity of early warning is reflected by the magnitude of the value, and the severity is used as a basis for quantitatively evaluating the performance of the ship lock equipment.
6. The method of claim 1, wherein in step 3, the lock device performance pre-warning rules are: setting a closed interval with an early warning value range of 0-1, wherein the magnitude of the numerical value reflects the severity of early warning, 0 indicates that the fault is unlikely to occur, 1 indicates that the fault is inevitable to occur, and according to the performance early warning classification of ship lock equipment, different inspection and equipment maintenance strategies are adopted for the performance early warning of different levels, and refinement analysis is carried out, different regular operation control modes and equipment fixed inspection and maintenance plans are generated through an intelligent operation platform, and corresponding equipment operation control modes and fixed inspection and maintenance plans are respectively defined for the early warning of faults, defects, hidden dangers and problems, and the method specifically comprises the following steps:
Step 3-1: regarding the early warning value between 0 and 0.35, the performance trend of the equipment is considered to be an unobvious decline trend, the level of the equipment is classified as a problem, and the condition that the performance trend of the equipment is unobvious decline or unstable is usually considered, the operation of the ship lock is not influenced negatively temporarily, and the problem cannot be determined;
step 3-2: for the early warning value between 0.35 and 0.55, the severity is considered to be lower, the level of the early warning value is divided into hidden danger, the performance is usually reduced due to the degradation, aging and other reasons of equipment, the trend is obvious, and if the early warning value is not processed for a long time, the operation efficiency of the equipment is reduced or even the operation is interrupted;
step 3-3: for the early warning value between 0.55 and 0.75, the equipment is considered to have middle and low risk of failure, the level is divided into 'defect', if the equipment is not processed, the operation efficiency of the ship lock equipment is possibly affected but no major accident is caused, and for the early warning, corresponding fixed inspection and maintenance plans are generated;
step 3-4: for an early warning value between 0.75 and 1, the equipment can be considered to have high risk or be in fault, the level of the equipment is divided into 'fault', relevant measures are immediately taken to solve the fault, and for the early warning, a fixed inspection tour inspection and overhaul plan is generated to deal with;
In step 3-1, the equipment operation control mode and the fixed inspection tour inspection and overhaul plan include: when faults occur, the system gives an alarm prompt, and meanwhile, the running system enters a protective running state, and only the running is completed, the faults must be removed after the running is finished, otherwise, the system is not allowed to run next time;
in step 3-2, the equipment operation control mode and the fixed inspection tour inspection and overhaul plan include: the inspection period is regulated, the acquisition of auxiliary performance values is increased, when a fault occurs, an alarm prompt is given by a system, meanwhile, the operation of a system part related to the fault is stopped, and the part can normally operate only after the fault is removed;
in step 3-3, the equipment operation control mode and the fixed inspection tour inspection and overhaul plan comprise: the inspection period is adjusted, the inspection plan is increased, the auxiliary performance value acquisition is increased, so that performance change conditions can be accurately positioned and tracked in real time, when faults occur, an alarm prompt is given by the system, meanwhile, running system equipment stops, if gate valve A equipment is in a middle position, the system stops running after critical equipment such as a gate valve is emergently closed, and the system can normally run after the faults are removed;
In step 3-4, the equipment operation control mode and the fixed inspection tour inspection and overhaul plan comprise: the attention of fault equipment is increased, the inspection period is adjusted, the maintenance plan is increased, the acquisition of auxiliary performance values is increased, when a fault occurs, the system gives an alarm prompt, meanwhile, the whole system enters a forbidden operation state, if the system equipment is running, the emergency operation state is entered, and meanwhile, the steps of a running program of the centralized control system are stopped and cleared.
7. The method of claim 1, wherein in step 3, coping with the policy further comprises: aiming at the early warning of faults, defects, hidden dangers and problems, corresponding equipment spare part storage strategies are respectively formulated, and the method comprises the following steps of:
(1) For the equipment performance early warning of the 'fault' level, the operation control mode has great influence on navigation of the ship lock, the reserve quantity of spare parts is determined according to the working condition, the installed quantity and the service life analysis of the spare parts, the stock is not allowed to be lacked, a quantitative storage strategy is adopted, namely a certain reserve quantity is required in the stock, and the stock is ordered and supplemented until the reserve quantity of the stock is reached once the spare parts are consumed;
(2) For the equipment performance early warning of the defect level, the operation control mode has larger influence on navigation of the ship lock, the maximum inventory and the minimum inventory are determined according to the installed quantity, the loss degree and the average service life, the inventory is reserved according to the maximum inventory, the minimum inventory is ensured, the strategy of replenishing the inventory to the maximum inventory is adopted, the quantitative storage strategy is adopted, namely, once-ordered goods are used as storage replenishing every 12 months, the maximum inventory is replenished, and the maximum reserve quota Q is adopted max =m×t×k, lowest reserve quota Q min ＝M×T d X K, where M is the average spare part month consumption, m=m/M T M is the installed number of equipment spare parts, M T The average service life of spare parts is determined by combining the design service life of equipment and the performance early warning value; t is the purchasing period, T d Is the supply period, K is the reserve coefficient of the spare part;
(3) For the equipment performance early warning of the hidden danger level, the operation control mode of the equipment performance early warning can not directly influence navigation, and a regular quantitative storage strategy is adopted, namely a certain reserve quantity is required to be reserved in the stock, and the reserve quantity calculation formula is adopted: q (Q) const M×t×k, where M is the average spare part month consumption, m=m/M T M is the installed number of equipment spare parts, M T The average service life of spare parts is determined by combining the design service life of equipment and the performance early warning value; t is a purchasing period, and K is a reserve coefficient of spare parts;
(4) For the equipment performance early warning of the 'problem' level, the operation control mode of the equipment performance early warning can not directly influence navigation, and a regular quantitative storage strategy is adopted, namely, a certain reserve amount is reserved in the stock, and the reserve amount calculation formula is adopted: q (Q) const =m×t×k, where M is the spare part month averageConsumption, m=m/M T M is the installed number of equipment spare parts, M T The average service life of spare parts is determined by combining the design service life of equipment and the performance early warning value; t is the purchasing period, and K is the reserve coefficient of the spare part.
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