CN103884371B - Trouble-shooter based on WIA PA wireless vibration instrument and method - Google Patents

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

Fault diagnosis device and method based on WIA-PA wireless vibration instrument

technical field

The invention relates to a method and device for performing equipment fault diagnosis. The device performs fault diagnosis based on vibration, and transmits vibration data to the host computer through the WIA-PA wireless network to further realize advanced diagnosis.

Background technique

In modern enterprises such as petroleum, chemical industry, metallurgy and electric power, fans, compressors, pumps, motors and other equipment are key production tools. Carrying out status detection and fault diagnosis of these equipment to ensure safe and reliable operation of the equipment can obtain Huge economic and social benefits. Vibration is destructive to these working equipment, such as rotor imbalance or impact, rolling and mutual friction between parts, gaps or looseness between parts, peeling or cracks on the surface of parts, etc. These vibrations will cause component failure or failure.

The vibration instrument senses the vibration and noise signals generated by the equipment through the vibration sensor directly installed on the surface of the machine, identifies the abnormal vibration amplitude and combines the database of the host computer to identify the faulty part and the fault type, so as to repair or replace the faulty or performance-degraded parts to avoid Losses due to downtime. For example, install the instrument to the deaerator pump, detect the vibration of the deaerator pump in real time, analyze the vibration signal to find potential faults of the pump such as unbalance, misalignment, bearing failure, etc., and realize condition-based maintenance.

Vibration diagnosis can detect faulty or performance-degraded parts in advance, replace or repair them in advance, reduce maintenance costs and avoid economic losses caused by sudden shutdown. The installation and wiring of traditional wired instruments is complicated, and the cost of cable purchase, laying and maintenance is high. The wireless instrument based on WIA-PA network can well meet the needs of system monitoring. The intelligent wireless network WIA (Wireless Networks for Industrial Automation) is based on the short-range wireless communication IEEE802.15.4 standard, uses free frequency bands, and solves the multipath effect caused by the reflection and scattering of wireless signals in large equipment, metal pipes, etc., as well as the operation of motors and equipment. Electromagnetic noise interferes with wireless communication, providing highly reliable and real-time wireless communication services. Intelligent wireless network WIA technology is especially suitable for industrial control and factory automation process control, and is widely used in petroleum, chemical, metallurgy, mining and other fields.

Contents of the invention

Aiming at the deficiencies of the prior art, the present invention provides a method and device for performing equipment fault diagnosis.

The technical solution adopted by the present invention to achieve the above purpose is: based on the fault diagnosis device of WIA-PA wireless vibration instrument, the industrial Ethernet is connected with the upper computer, server, and wireless gateway, and the wireless gateway is connected with the large rotating equipment. The wireless vibration meter communicates wirelessly.

The equipment includes pumps, electric motors, compressors.

The wireless vibration meter includes: a microcontroller is connected to a reset circuit, a clock circuit, a memory circuit, an A/D conversion circuit, and a wireless transceiver module; a vibration sensor is connected to an input end of a signal processing circuit, and the output end of the signal processing circuit is connected to an A /D conversion circuit analog input connection.

The fault diagnosis method based on WIA-PA wireless vibration instrument includes the following steps:

The gateway searches for the wireless vibration instrument, and the wireless vibration instrument enters the WIA wireless network;

If the wireless vibration instrument is used for the first time, the upper computer sets the diagnostic process parameters and sends it to the instrument, and the instrument saves the diagnostic process parameters; if it is not the first use, the wireless vibration instrument judges whether the running time has reached its own data acquisition refresh cycle; If it is not reached, the diagnosis will end; if it is reached, the wireless vibration instrument will be started to complete a processing operation;

The upper computer receives the data processed by the wireless vibration instrument through the industrial Ethernet, and sends an end command to the wireless vibration instrument; then uploads the data to the fault diagnosis database for fault analysis, and realizes the fault diagnosis of the wireless vibration instrument.

The diagnostic process parameters include meter refresh rate, meter working mode, fundamental frequency of the device under test, frequency multiplier of fault analysis spectrum, data sampling frequency, and data sampling length.

The wireless vibration meter processing operation includes the following steps:

The microcontroller in the wireless vibration meter converts the voltage signal of the sensor received by the A/D conversion circuit in the meter into sensor feedback data according to the loaded data sampling frequency and data sampling length for data calibration and sensor status judgment:

Data calibration is specifically to convert sensor feedback data into vibration acceleration signals;

The judgment of the sensor state is as follows: judge whether the sensor is in a normal state according to the sensor feedback data; if it is abnormal, do not start the instrument to work; if it is normal, use the Fourier transform method to convert the vibration data into a spectrum;

The wireless vibration instrument requests the WIA wireless network to send a collection calculation result through the wireless transceiver module; after the data transmission is completed, the wireless vibration instrument finishes processing and enters a dormant state.

The method of transforming the vibration data into frequency spectrum data by using the Fourier transform method specifically includes: converting the vibration acceleration signal into the vibration amplitude in the time domain, and applying the fast Fourier transform to obtain the frequency spectrum in the frequency domain.

The collection operation results include vibration amplitude data and frequency spectrum.

The obtaining of the fault diagnosis result comprises the following steps:

According to the vibration amplitude data of each data acquisition refresh cycle, the vibration trend graph is summarized, and whether there is abnormal vibration is judged according to the vibration threshold; if the threshold is exceeded, the abnormal data is input into the fault diagnosis database to obtain the cause of the fault, and obtained through the table number of the instrument point of failure.

The present invention has the following beneficial effects and advantages:

1. The entire device is applied to equipment health status detection, which improves the cost and efficiency of parts maintenance at low cost and high efficiency.

2. The wireless vibration meter can intelligently realize the main power consumption chip power control, wireless module power control and sensor power control functions of the meter, and then solve the low power consumption demand of the self-powered wireless meter to improve the working life of the meter battery.

Description of drawings

Fig. 1 system block diagram of fault diagnosis device system of the present invention;

Fig. 2 realizes the wireless vibration meter network schematic diagram of this device;

Fig. 3 realizes the structural block diagram of the wireless vibration instrument circuit of this device;

Fig. 4 realizes the wireless vibration instrument workflow block diagram of this device;

Fig. 5 is a block diagram of the working flow of the fault diagnosis device system of the present invention.

detailed description

The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments.

A fault diagnosis method and device based on a WIA-PA wireless vibration instrument, including a vibration sensor directly installed on the surface of a machine for sensing vibration signals, a controller for collecting and processing vibration signals, and a device connected to a WIA-PA wireless network The wireless transceiver module is a host computer carrying advanced fault identification and diagnosis methods.

The invention provides a fault diagnosis method and device, wherein the vibration instrument based on the WIA-PA wireless network realizes the collection and processing of diagnostic data, and the diagnosis and monitoring upper computer software realizes the fault diagnosis based on the data. The invention is used for monitoring the health status of industrial equipment during operation, identifying faults and components with reduced performance, and repairing or replacing them before faults occur.

FIG. 1 is a system topology diagram of a fault diagnosis method and device including a wireless vibration meter 19 for fault monitoring and a monitoring and diagnosis system 11 . The wireless vibration instrument is connected to the monitored equipment 23, 24, 25 through the sensor interface 20, 21, 22, and uses the acceleration sensor to sense the vibration signal. The monitored equipment can be pumps, motors, compressors and other equipment. The monitoring and diagnosis system 11 includes industrial computers, operating systems, fault analysis application software, data storage software, etc., stores, calculates and analyzes the vibration data sent through the WIA wireless gateway 15, and then identifies faulty components and fault levels. Background WIA server 12, industrial Ethernet 14, WIA wireless gateway 15, wireless vibration instrument 19 form WIA wireless network. Background WIA server 12 comprises computer, operating system and user application software, file log etc. It is used to complete the configuration of equipment, control of equipment under the network, detection information collection and analysis, data storage and other functions. The user sends the corresponding information command to the instrument in the WIA wireless network through the WIA server client. The WIA wireless gateway is connected to the industrial Ethernet 14 through the network interface 13, and then communicates with the background WIA server 12 and the vibration monitoring system 11. A gateway can connect multiple wireless vibration instruments through wireless sending and receiving signals 16, which facilitates the realization of multi-unit equipment monitoring and networking applications in factories. For example, the wireless vibration instruments 17, 18, 19 in the figure can realize the health status monitoring of the motor and shaft of the deaeration pump unit, and send the vibration data of the respective test points to the WIA wireless gateway 15 by connecting to the WIA wireless network. Then the data is uploaded to the monitoring and diagnosis system 11 through the industrial Ethernet to complete the functions of the entire monitoring system.

Fig. 2 is a schematic diagram of a wireless vibration meter network for realizing the device. For example, for a deaeration pump unit in a thermal power plant workshop, the vibration sensor 31 is directly installed on the monitoring point of the device under test 25, such as the X and Y directions of the motor. The wireless vibration meter 19 is connected to the vibration sensor through the sensor interface 30, which contains the sensor power supply and the electrical signal for sensing the vibration. The wireless vibration meter 19 provides working power for the sensor and receives electrical signals fed back by the sensor. Instruments and sensors are installed nearby to prevent noise interference and loss during signal transmission. After the signal is processed by the local signal processing module 28 and data processing module 27 of the wireless vibration instrument, it is uploaded to the WIA wireless gateway in the workshop of the deaeration pump unit via the WIA network 29, and then connected to the background server in the control room and the diagnostic host computer through the network interface to realize Monitoring the health status of the unit simplifies the on-site power supply and signal transmission wiring, saving costs.

Fig. 3 is a block diagram of the circuit structure of the wireless vibration meter 19 realizing the device. It consists of microcontroller 32, vibration sensor 31, signal processing circuit 37, A/D conversion circuit 36, wireless transceiver module 39, power circuit 38, wireless module power supply 41, sensor power supply 40 and other circuit modules. The sensor power supply 40 module of the instrument provides working power for the vibration sensor 31, and a power control function is designed in the module to ensure the low power consumption of the instrument. The signal processing circuit 37 in the meter implements functions such as signal acquisition, hardware filtering, and operational amplification, so that the signal can meet the input requirements of the A/D conversion circuit 36 . The A/D conversion circuit 36 realizes the conversion and detection function of analog signal to digital signal, and the conversion result is transmitted through the digital bus between the microcontroller 32 and the A/D conversion circuit 36 . The microcontroller 32 completes the vibration amplitude calculation, and calculates the frequency spectrum data of the vibration signal according to the known sampling frequency and sampling length. The peripheral circuits of the microcontroller 32 include a reset circuit 33 , a clock circuit 34 , a memory circuit 35 and other small system circuits of the microcontroller. The memory circuit 35 includes a cache intermediate data memory and a memory for loading instrument programs and configuration parameters. The microcontroller 32 starts data collection and calculation according to pre-configured parameters and transmits data to the WIA wireless network through the peripheral wireless transceiver module 39 . The power supply of the wireless transceiver module 39 is also provided by the instrument, and the instrument is designed with a power control function to realize the low-power operation of the wireless module according to the WIA network status. At the same time, the instruction information used in work and the configuration information of the instrument are issued through the WIA wireless network, and the microcontroller 32 receives and analyzes the command according to the private protocol and updates the local configuration table of the instrument, so that the user configuration can be saved.

Fig. 4 is a block diagram of the working process of the wireless vibration instrument realizing the device. The wireless vibration meter 19 is designed with a power management function, and controls the meter program startup 45 according to the corresponding configuration (whether the meter working mode is power-saving mode or normal mode) or user instruction information. After the instrument is started, it is necessary to execute the instrument initialization 46, which includes loading the startup program of the microcontroller 32 and loading configuration parameter information, including the instrument data acquisition frequency, data acquisition length, data refresh rate, the fundamental frequency of the analyzed equipment, the number of analysis multipliers, Instrument working mode, identifying the current operating instructions of the instrument, etc. After the initialization is completed, the microcontroller in the instrument starts the data collection 47 process according to the loaded sampling frequency and length. The collection process includes data calibration and sensor status judgment. The sensor status judgment is to judge whether the sensor bias voltage is normal; and then determine whether to start the data collection process. Processing 48 process promptly does not start data processing if the sensor is not in place or abnormal. Data calibration is to convert the received voltage signal into the corresponding vibration acceleration signal according to the A/D converter in the instrument; judge whether the sensor is in place and whether the power supply is normal, if abnormal, do not start the instrument to work. Data processing 48 mainly converts vibration data into spectrum data, including digital filtering, FFT (fast Fourier transform), wavelet transform and other data operation and processing algorithms, that is, firstly, according to the analysis of fundamental frequency and multiplier, sampling frequency and sampling length. FFT transformation, the transformation result is completed by wavelet transformation and then transmitted through the WIA network; specifically, sensor data is collected according to the sampling frequency and sampling length, and the vibration amplitude is calculated according to the obtained time-domain data array; and the fast Fourier transform FFT is applied Obtain the spectrum that conforms to the fundamental frequency of the equipment under test and the multiplier of the fault analysis spectrum: apply fast Fourier transform to complete the conversion from time domain to frequency domain data, and then judge the cause of the fault based on the spectrum; among them, the set value of the sampling frequency is at least The fundamental frequency is three times of the rotating speed of the tested equipment, and the fundamental frequency is the rotating speed of the tested equipment. The multiplier of the fault analysis spectrum needs to be set by professionals according to the type of equipment and possible faults.

After finishing the processing, the instrument starts the process 49 of connecting to the WIA wireless network through the wireless transceiver module 39, and requests the network to send a collection and calculation result. The data transmission 50 follows the WIA network data transmission private protocol. In order to improve the reliability of data transmission, a step-by-step CRC check and retransmission mechanism is designed in the transmission protocol, and corresponding alarm and log information are designed in the user application interface to facilitate the entire diagnosis system. maintain. After data transmission and handshake information interaction are completed, the instrument program hangs up and enters the end 51 process. At this time, the entire instrument enters a dormant state except for management and control functions to save power consumption, and the program waits for the next startup.

Fig. 5 is a block diagram of the working flow of the fault diagnosis device system of the present invention. Start the WIA gateway control terminal software 53, first complete the WIA network configuration 54, and then search for the wireless vibration meter network access 55 according to the wireless ID of the meter, and the meter and the wireless gateway complete the handshake communication. The user (the user refers to the engineer who uses the diagnostic system; judge whether to modify the process parameters according to whether the diagnostic system is installed and used for the first time) first judges whether there are any diagnostic process parameters that need to be modified. If modification is required, execute 56 to send the parameter configuration and save it Parameter configuration 57; if no modification is required, then judge whether the diagnostic data acquisition refresh cycle is satisfied, if not, then directly end 60 this operation, if satisfied, then start the wireless vibration instrument 58 to perform an operation. After the operation is completed, the upper computer receives the data returned by the instrument and issues a command to end the work of the wireless vibration instrument. After completion, the data is uploaded to the fault diagnosis software database 59 for fault diagnosis and viewing of historical data. The uploaded data includes vibration amplitude data and frequency spectrum data; the fault diagnosis software database 59 summarizes a vibration trend graph according to the vibration amplitude data of each refresh cycle, and this figure shows the vibration amplitude when the sensor is in a normal working state; There is abnormal vibration; input the fault diagnosis database according to the vibration spectrum data of each refresh cycle, the database is composed of sensor fault data, including the spectrum data and the corresponding fault cause, so the fault cause can be obtained by inputting the spectrum data; The table number of the vibration meter can get the fault 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.