CN108805300A - Numerically controlled machine remote live collaboration fault diagnosis and maintenance system - Google Patents
Numerically controlled machine remote live collaboration fault diagnosis and maintenance system Download PDFInfo
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Abstract
本发明涉及一种数控机床远程实时协作故障诊断及维修系统,利用LabVIEW虚拟仪器技术、Node.js后台服务器技术、流媒体技术和iOS移动终端技术组建远程故障诊断系统,使数据采集、传输和处理集成到一个共享平台,使故障诊断专家的工作摆脱了空间位置和条件的限制,通过网络把所采集到的数据实时地发送到远程云服务器,再由云服务器进行存储和分发。针对实时协作,搭建了一个协作交流平台,支持现场工程师和远程专家的实时在线文字交流以及图片和文件共享。同时,现场工程时利用移动设备采集故障现场图片、视频等多媒体数据并发送到云端服务器,远程诊断专家可以实时查看各种多媒体数据。另外,本系统采用HTTPS加密技术,保障了数据的安全传输。
The present invention relates to a remote real-time cooperative fault diagnosis and maintenance system for CNC machine tools. The remote fault diagnosis system is established by using LabVIEW virtual instrument technology, Node.js background server technology, streaming media technology and iOS mobile terminal technology to enable data collection, transmission and processing Integrated into a shared platform, the work of fault diagnosis experts is freed from the limitations of space and conditions, and the collected data is sent to a remote cloud server in real time through the network, and then stored and distributed by the cloud server. For real-time collaboration, a collaborative communication platform has been built to support real-time online text communication and picture and file sharing between on-site engineers and remote experts. At the same time, during on-site engineering, mobile devices are used to collect multimedia data such as pictures and videos of the fault site and send them to the cloud server. Remote diagnostic experts can view various multimedia data in real time. In addition, the system uses HTTPS encryption technology to ensure the safe transmission of data.
Description
技术领域technical field
本发明涉及一种数控机床维修技术,特别涉及一种基于云服务技术的数控机床远程实时协作故障诊断及维修系统。The invention relates to a CNC machine tool maintenance technology, in particular to a remote real-time collaborative fault diagnosis and maintenance system for a CNC machine tool based on cloud service technology.
背景技术Background technique
在数控机床调试和使用的过程中,故障诊断是非常重要的组成部分,是目前限制数控机床正常工作的主要因素之一。数控机床在工作过程中,受到热、力、摩擦、磨损等多种作用,其运行状态非常复杂,出现故障在所难免。因此,必须在出现故障后,快速、高效的做出判断,采取相应的措施来解决故障以避免因故障而导致更严重的经济损失,这样做可大大提高机床设备的运行可靠性,从而提高机床设备乃至整个企业的生产效率。In the process of debugging and using CNC machine tools, fault diagnosis is a very important part, and it is one of the main factors that limit the normal operation of CNC machine tools. During the working process of CNC machine tools, they are subjected to various effects such as heat, force, friction, and wear. Their operating states are very complicated, and failures are inevitable. Therefore, it is necessary to make a quick and efficient judgment after a fault occurs, and take corresponding measures to solve the fault to avoid more serious economic losses due to the fault. This can greatly improve the operating reliability of the machine tool equipment, thereby improving the The productivity of the equipment and the entire enterprise.
尽管在数控机床远程诊断方面,已经有很多机构和研究人员做出了相当多的贡献和研究,但是现阶段,我国相关企业比较少推出远程诊断系统,而且在应用中并没有获得预期的效果,究其原因,其存在的问题包括:(1)缺乏实时性:无法保障故障现场大量特征信号数据的实时传输;(2)缺乏协作性:远程诊断专家很难和现场工程师进行实时有效的沟通协作,导致维修无法及时、高效的进行;(3)缺乏直观性:远程诊断专家仅仅根据机床运行数据和传感器数据很难判断出机床故障的原因,需要直观性更强的媒体数据如图片、视频等辅助诊断;(4)缺乏安全性:由于互联网的开放性,竞争对手很有可能会利用网络系统漏洞来窃取商业机密,给企业带来损失。Although many institutions and researchers have made considerable contributions and researches on the remote diagnosis of CNC machine tools, at this stage, relatively few companies in my country have launched remote diagnosis systems, and the expected results have not been obtained in the application. The reasons for this include: (1) lack of real-time performance: the real-time transmission of a large number of characteristic signal data at the fault site cannot be guaranteed; (2) lack of collaboration: it is difficult for remote diagnostic experts to communicate and collaborate effectively with field engineers in real time (3) Lack of intuition: It is difficult for remote diagnosis experts to judge the cause of machine failure based on machine tool operating data and sensor data, and requires more intuitive media data such as pictures, videos, etc. Auxiliary diagnosis; (4) Lack of security: due to the openness of the Internet, competitors are likely to use network system loopholes to steal business secrets and bring losses to the enterprise.
与以往传统的故障诊断相比较,远程实时协作诊断的优势体现在使企业能够在机床发生故障后第一时间获得技术支持,同时数控机床诊断专家能够更加快速、有效地得到企业设备的第一手数据资料,而不必亲临故障现场。它提供了一个多方面故障信息的共享平台,及时沟通了机床运行现场人员、诊断专家、管理部门和设备制造厂家,服务于机床制造、运行和维修过程中,充分利用了高速网络作为信息传输载体,实现了实时的故障机床信息的收集、传递和共享,极大的缩短了故障诊断的时间。Compared with the traditional fault diagnosis in the past, the advantages of remote real-time collaborative diagnosis are reflected in enabling enterprises to obtain technical support immediately after a machine tool fails, and at the same time, CNC machine tool diagnosis experts can get first-hand information on enterprise equipment more quickly and effectively. data without having to visit the fault site. It provides a multi-faceted fault information sharing platform, communicates with machine tool operation site personnel, diagnostic experts, management departments and equipment manufacturers in a timely manner, serves the process of machine tool manufacturing, operation and maintenance, and makes full use of high-speed networks as information transmission carriers , Realized the collection, transmission and sharing of real-time faulty machine tool information, which greatly shortened the time for fault diagnosis.
数控机床远程实时协作诊断系统的功能就是远程诊断在异地发生的数控机床事故故障,主要通过故障现场维修人员和远程诊断专家合作完成。远程诊断专家根据运行机床的状态信号、故障信息以及现场多媒体声像信号,可以及时制定出相应故障设备的维修解决方案,现场维修人员可以在远程诊断专家的指导下对故障设备进行调整和维修,直至排除故障。因此,远程实时协作诊断技术是计算机网络技术、通信技术、信号处理技术、传感器监测技术、流媒体技术等多项技术相融合而形成的一个新的技术领域。The function of the remote real-time collaborative diagnosis system for CNC machine tools is to remotely diagnose the accidents and faults of CNC machine tools that occur in different places, mainly through the cooperation of on-site maintenance personnel and remote diagnosis experts. According to the status signal, fault information and on-site multimedia audio-visual signal of the running machine tool, the remote diagnosis experts can formulate the maintenance solution for the corresponding faulty equipment in time. The on-site maintenance personnel can adjust and repair the faulty equipment under the guidance of the remote diagnosis expert. until troubleshooting. Therefore, remote real-time collaborative diagnosis technology is a new technical field formed by the fusion of computer network technology, communication technology, signal processing technology, sensor monitoring technology, streaming media technology and other technologies.
数控机床远程实时协作诊断系统为不同地域间任务关联的多个技术人员和维修专家提供一个广域网支持的故障协作诊断环境,使他们能同时对某项维修案例进行高效准确的诊断,并指导设备维修。具体来说,就是将信号处理及计算机网络编程技术相结合,一方面,现场维修人员在远程专家的实时指导下,在故障机床上安装传感器,并将实时采集的信号数据发送到云端服务器并由云端服务器进行必要的数据处理;另一方面,多位远程专家可以通过网页浏览器查看维修现场视频和传感器实时数据并指导现场工程师的维修工作,从而实现故障的快速诊断与及时维修。要实现上述的要求,系统设计的主要功能需求包括:故障案例跟踪管理、故障机床设备特征信号采集及实时展示、故障现场多媒体信号采集分享、故障现场的视频实时监控、在线故障诊断交流平台、用户管理。The remote real-time collaborative diagnosis system of CNC machine tools provides a wide area network-supported fault collaborative diagnosis environment for multiple technicians and maintenance experts associated with tasks in different regions, enabling them to perform efficient and accurate diagnosis of a maintenance case at the same time and guide equipment maintenance . Specifically, it is the combination of signal processing and computer network programming technology. On the one hand, under the real-time guidance of remote experts, on-site maintenance personnel install sensors on faulty machine tools, and send the real-time collected signal data to the cloud server for further analysis. The cloud server performs the necessary data processing; on the other hand, multiple remote experts can view the maintenance site video and sensor real-time data through the web browser and guide the maintenance work of the on-site engineers, so as to realize rapid fault diagnosis and timely maintenance. To achieve the above requirements, the main functional requirements of the system design include: fault case tracking management, fault machine tool equipment characteristic signal collection and real-time display, fault site multimedia signal collection and sharing, fault site video real-time monitoring, online fault diagnosis communication platform, user manage.
因此,研究数控机床远程实时协作诊断系统的主要目的和意义在于:1)诊断专家可以跨地域完成故障诊断,提高了诊断的及时性、准确性和可靠性;2)完成诊断后,可利用诊断案例数据库对企业技术人员进行培训,提高其机床维修实践水平;3)远程诊断可实现全球范围内的诊断数据和诊断知识的共享;4)科研机构的诊断专家可以获得宝贵的现场经验和数据,充实理论和技术研究。Therefore, the main purpose and significance of researching the remote real-time collaborative diagnosis system of CNC machine tools is: 1) Diagnosis experts can complete fault diagnosis across regions, which improves the timeliness, accuracy and reliability of diagnosis; The case database trains enterprise technicians to improve their machine tool maintenance practice; 3) remote diagnosis can realize the sharing of diagnostic data and diagnostic knowledge worldwide; 4) diagnostic experts of scientific research institutions can obtain valuable on-site experience and data, Enrich theoretical and technical research.
发明内容Contents of the invention
本发明是针对数控机床远程诊断的重要性的问题,提出了一种数控机床远程实时协作故障诊断及维修系统,实现使数据采集、传输和处理集成到一个共享平台,支持现场工程师和远程专家的实时在线文字交流以及图片和文件共享,远程诊断专家可以实时查看各种多媒体数据,并保障数据的安全传输。The present invention is aimed at the importance of remote diagnosis of CNC machine tools, and proposes a remote real-time collaborative fault diagnosis and maintenance system for CNC machine tools, which realizes the integration of data collection, transmission and processing into a shared platform, and supports on-site engineers and remote experts. Real-time online text communication and picture and file sharing, remote diagnosis experts can view various multimedia data in real time, and ensure the safe transmission of data.
本发明的技术方案为:一种数控机床远程实时协作故障诊断及维修系统,包括上下交互的三层,The technical solution of the present invention is: a remote real-time collaborative fault diagnosis and maintenance system for CNC machine tools, including three layers of upper and lower interaction,
第一层数据层:提供故障案例数据、传感器历史数据的存储和修改、用户相关数据存储,远程诊断数据采集系统中温度传感器、电流传感器、振动传感器分别监测数控机床振动信号、电流信号、温度信号,通过DAQ数据采集卡采集各信号,远程诊断数据采集系统将数据传输至远程诊断云服务器系统,根据云端服务器系统提供的接口实现云端故障列表的获取;The first layer of data layer: provide fault case data, storage and modification of sensor historical data, user-related data storage, and remote diagnosis data acquisition system for temperature sensors, current sensors, and vibration sensors to monitor vibration signals, current signals, and temperature signals of CNC machine tools , each signal is collected through the DAQ data acquisition card, the remote diagnosis data acquisition system transmits the data to the remote diagnosis cloud server system, and the cloud fault list is obtained according to the interface provided by the cloud server system;
第二层应用逻辑层:负责云端服务器、远程传感器和故障诊断浏览器之间的数据处理和传递, 包括远程诊断云端服务器系统和远程诊断视频监控流媒体服务器系统,远程诊断移动终端系统实现流媒体数据采集、故障现场视频信号的实时采集和推流,远程诊断视频监控流媒体服务器系统采用实时方式,媒体文件数据是以流的形式进行传输,流数据缓存在客户端内存中,实时的播放流数据,实现边下载边播放;The second layer of application logic layer: responsible for data processing and transmission between cloud server, remote sensor and fault diagnosis browser, including remote diagnosis cloud server system and remote diagnosis video monitoring streaming media server system, remote diagnosis mobile terminal system to realize streaming media Data acquisition, real-time acquisition and streaming of video signals at the fault site, remote diagnosis video monitoring streaming media server system adopts real-time mode, media file data is transmitted in the form of stream, stream data is cached in the client memory, real-time playback stream Data, realize playing while downloading;
第三层客户层:直接通过web浏览器输入地址,实现与现场维修工程师的沟通并对机床的诊断。The third layer of customer layer: directly enter the address through the web browser, realize the communication with the on-site maintenance engineer and diagnose the machine tool.
所述远程诊断数据采集系统获取云端服务器的故障列表,然后现场维修工程师选择对应的故障案例进行数据采集工作,远程诊断数据采集系统Labview采用HTTP协议与云端服务器进行通信来获取故障列表数据,利用LabVIEW下的HTTP网络工具包和Socket网络工具包,根据云端服务器提供的接口实现云端故障列表的获取和传感器数据的实时传输。The remote diagnostic data acquisition system obtains the fault list of the cloud server, and then the on-site maintenance engineer selects the corresponding fault case to carry out the data collection work. The remote diagnostic data acquisition system Labview uses the HTTP protocol to communicate with the cloud server to obtain the fault list data. The HTTP network toolkit and Socket network toolkit under the cloud server realize the acquisition of the cloud fault list and the real-time transmission of sensor data according to the interface provided by the cloud server.
所述远程诊断云端服务器系统采用B/S架构,采用模型-视图-控制器设计模式;在数据层,使用Mongoose 框架来操作MongoDB 数据库;基于Node.js 的云服务器的前端的逻辑和页面效果采用HTML5+CSS3+Bootstrap+AngularJS +Jquery+WebSocket 来实现;云端服务器的后台采用基于Node.js 的网页框架Express。The remote diagnosis cloud server system adopts B/S architecture and adopts the model-view-controller design pattern; in the data layer, the Mongoose framework is used to operate the MongoDB database; the front-end logic and page effects of the cloud server based on Node.js adopt HTML5+CSS3+Bootstrap+AngularJS +Jquery+WebSocket to achieve; the background of the cloud server uses the Node.js-based web framework Express.
所述远程诊断视频监控流媒体服务器系统采用流媒体技术,实现故障现场的音视频数据采集、流媒体服务器端的流传输和远程专家播放端的音视频获取;The remote diagnosis video monitoring streaming media server system adopts streaming media technology to realize audio and video data collection at the fault site, streaming transmission at the streaming media server end and audio and video acquisition at the remote expert playback end;
音视频数据采集:采集故障现场机床的声音和图像,采集后的音视频数据转换成字节码、混合并压缩,最后封装成音视频格式,就是所谓的音视频压缩编码;编码压缩后的音视频数据,转换成码流然后推流到流媒体服务器;Audio and video data collection: collect the sound and image of the machine tool at the fault site, convert the collected audio and video data into byte codes, mix and compress them, and finally package them into audio and video formats, which is the so-called audio and video compression coding; the compressed audio and video data Video data, converted into code stream and then pushed to the streaming media server;
流媒体服务器端的流传输,把维修现场的音视频流分发传输给所有观看者;The stream transmission on the streaming media server side distributes and transmits the audio and video streams on the maintenance site to all viewers;
播放端的流媒体数据获取:远程专家获取流媒体服务器的流媒体数据,然后对流进行解析解码播放。Acquisition of streaming media data at the playback end: the remote expert obtains the streaming media data of the streaming media server, and then parses, decodes, and plays the stream.
所述远程诊断移动终端系统采用Model-View-Controller架构,分为5 个部分,分别是界面UI 层、控制层、数据层、网络层和工具层;Described remote diagnosis mobile terminal system adopts Model-View-Controller framework, is divided into 5 parts, is interface UI layer, control layer, data layer, network layer and tool layer respectively;
界面UI 层负责展示各种界面,是数据的表达者;Interface The UI layer is responsible for displaying various interfaces and is the expresser of data;
控制层是核心,负责控制其他各层之间的协调工作以及事件控制;The control layer is the core, responsible for controlling the coordination between other layers and event control;
数据层负责数据模型定义和数据持久化的工作,针对不同的数据类型和特性,选择合适的方式进行存储,并且提供给外界合适的接口来存储或提取数据;The data layer is responsible for data model definition and data persistence, chooses an appropriate way to store different data types and characteristics, and provides an appropriate interface to the outside world to store or extract data;
网络层负责将网络请求、相关业务、数据的处理封装起来并对外界暴露统一的接口。The network layer is responsible for encapsulating network requests, related services, and data processing and exposing a unified interface to the outside world.
本发明的有益效果在于:本发明数控机床远程实时协作故障诊断及维修系统,利用LabVIEW虚拟仪器技术、Node.js后台服务器技术、流媒体技术和iOS移动终端技术组建远程故障诊断系统,可以使数据采集、传输和处理集成到一个共享平台,使故障诊断专家的工作摆脱了空间位置和条件的限制,通过网络把所采集到的数据实时地发送到远程云服务器,再由云服务器进行存储和分发。针对实时协作,本系统搭建了一个协作交流平台,支持现场工程师和远程专家的实时在线文字交流以及图片和文件共享。同时,现场工程时可以利用移动设备采集故障现场图片、视频等多媒体数据并发送到云端服务器,远程诊断专家可以实时查看各种多媒体数据。另外,本系统采用HTTPS加密技术,保障了数据的安全传输。The beneficial effect of the present invention is that: the remote real-time cooperative fault diagnosis and maintenance system of CNC machine tools of the present invention utilizes LabVIEW virtual instrument technology, Node. Acquisition, transmission and processing are integrated into a shared platform, freeing the work of fault diagnosis experts from the constraints of space and conditions, and sending the collected data to a remote cloud server in real time through the network, and then stored and distributed by the cloud server . For real-time collaboration, this system builds a collaborative communication platform to support real-time online text communication and picture and file sharing between on-site engineers and remote experts. At the same time, during on-site engineering, mobile devices can be used to collect multimedia data such as pictures and videos of the fault site and send them to the cloud server. Remote diagnostic experts can view various multimedia data in real time. In addition, the system uses HTTPS encryption technology to ensure the safe transmission of data.
附图说明Description of drawings
图1为本发明数控机床远程实时协作故障诊断及维修系统功能框架图;Fig. 1 is the function frame diagram of remote real-time cooperative fault diagnosis and maintenance system of numerical control machine tool of the present invention;
图2为本发明系统架构图;Fig. 2 is a system architecture diagram of the present invention;
图3为本发明云服务器技术架构图;Fig. 3 is a technical framework diagram of the cloud server of the present invention;
图4为本发明流媒体系统的关键流程;Fig. 4 is the key process of streaming media system of the present invention;
图5为本发明移动终端软件架构图。FIG. 5 is a software architecture diagram of the mobile terminal of the present invention.
具体实施方式Detailed ways
图1为本发明数控机床远程实时协作故障诊断及维修系统功能框架图,本发明的主要作业对象为多种数控机床型号的故障诊断和维修,该系统采用三层系统架构,第一层为数据服务层,主要提供故障案例数据、传感器历史数据的存储和修改、用户相关数据存储;第二层为应用逻辑层,又称为中间层,负责云端服务器、远程传感器和故障诊断浏览器之间的数据处理和传递;第三层为客户层,本系统远程不需要安装客户端程序,直接在浏览器输入地址就可在远程实现与现场维修工程师的沟通并对机床诊断。具体而言,为了实现以上系统架构,本发明包括四个子系统,数据采集系统主要监测振动信号、电流信号、温度信号等;远程诊断云端服务器系统主要是为了实现故障案例管理,故障图片、视频、文件上传共享,传感器数据实时传输,以及实时交流;远程诊断视频监控流媒体系统主要为了实现音视频数据采集,流媒体服务器端的流传输,播放端的流媒体数据获取;远程诊断移动终端系统,该系统基于iOS移动设备平台,实现故障现场图片、视频的拍摄和上传,实时流媒体信号的采集传输,故障列表和详细信息的展示以及故障最新信息的推送通知等功能。Fig. 1 is the functional frame diagram of the remote real-time collaborative fault diagnosis and maintenance system of CNC machine tools of the present invention. The main operating objects of the present invention are fault diagnosis and maintenance of various CNC machine tool models. The system adopts a three-layer system architecture, and the first layer is data The service layer mainly provides fault case data, storage and modification of sensor historical data, and user-related data storage; the second layer is the application logic layer, also known as the middle layer, responsible for the communication between cloud servers, remote sensors, and fault diagnosis browsers. Data processing and transmission; the third layer is the client layer. This system does not need to install the client program remotely, and can communicate with the on-site maintenance engineer and diagnose the machine tool remotely by directly inputting the address in the browser. Specifically, in order to realize the above system architecture, the present invention includes four subsystems. The data acquisition system mainly monitors vibration signals, current signals, temperature signals, etc.; the remote diagnosis cloud server system is mainly to realize fault case management, fault pictures, videos, File upload and sharing, real-time transmission of sensor data, and real-time communication; remote diagnostic video surveillance streaming media system is mainly to realize audio and video data collection, streaming media server-side streaming, and streaming media data acquisition at the playback end; remote diagnostic mobile terminal system, the system Based on the iOS mobile device platform, it realizes the shooting and uploading of fault scene pictures and videos, the collection and transmission of real-time streaming media signals, the display of fault lists and detailed information, and the push notification of the latest fault information.
整个系统采用具体的架构如图2所示,具体的来讲可以分为上下交互的三层,其中第一层是数据层,包括MongoDB数据库和File文件存储;与中间层进行数据交互,主要提供故障案例数据、传感器历史数据的存储和修改、用户相关数据存储;第二层应用逻辑层,也称为中间层,包括远程诊断云端服务器系统和远程诊断视频监控流媒体服务器系统,负责云端服务器、远程传感器和故障诊断浏览器(客户层)之间的数据处理和传递,本系统是面向多种数控机床型号的故障诊断,因此采用外接的传感器和数据采集设备,利用已有的数据采集卡、传感器、LabVIEW 虚拟仪器实现机床特征信号的数据采集,并传输至云端服务器,同时,为了获得现场实时视频,需要流媒体数据采集设备,因此在移动终端上设计了远程诊断客户端软件系统,支持故障现场视频信号的实时采集和推流,同时该软件具有故障案例展示、照片和视频拍摄及上传、故障信息推送提醒等功能。。第三层客户层,本系统远程不需要安装客户端程序,直接可在web浏览器输入地址就可以在远程实现与现场维修工程师的沟通并对机床的诊断。The specific architecture of the whole system is shown in Figure 2. Specifically, it can be divided into three layers of upper and lower interaction. The first layer is the data layer, including MongoDB database and File file storage; data interaction with the middle layer mainly provides Fault case data, storage and modification of sensor historical data, and user-related data storage; the second layer of application logic layer, also known as the middle layer, includes remote diagnosis cloud server system and remote diagnosis video monitoring streaming media server system, responsible for cloud server, Data processing and transmission between remote sensors and fault diagnosis browser (client layer). This system is oriented to fault diagnosis of various CNC machine tool models. Therefore, external sensors and data acquisition equipment are used, and existing data acquisition cards, Sensors and LabVIEW virtual instruments realize the data collection of machine tool characteristic signals and transmit them to the cloud server. At the same time, in order to obtain on-site real-time video, streaming media data collection equipment is required. Therefore, a remote diagnosis client software system is designed on the mobile terminal to support fault diagnosis. Real-time collection and streaming of on-site video signals. At the same time, the software has functions such as failure case display, photo and video shooting and uploading, and failure information push reminder. . The third layer is the client layer. This system does not need to install the client program remotely. You can directly enter the address in the web browser to communicate with the on-site maintenance engineer and diagnose the machine tool remotely.
为了实现上述目的,数据层包括远程诊断数据采集系统,它既可以将数据传输至远程诊断云服务器系统,又可以根据云端服务器提供的接口实现云端故障列表的获取;应用逻辑层包括远程诊断云端服务器系统和远程诊断视频监控流媒体服务器系统;远程诊断移动终端系统是为了实现流媒体数据采集,支持故障现场视频信号的实时采集和推流,同时该软件具有故障案例展示、照片和视频拍摄及上传、故障信息推送提醒等功能。其中:In order to achieve the above purpose, the data layer includes a remote diagnosis data acquisition system, which can not only transmit data to the remote diagnosis cloud server system, but also realize the acquisition of the cloud fault list according to the interface provided by the cloud server; the application logic layer includes the remote diagnosis cloud server System and remote diagnosis video monitoring streaming media server system; remote diagnosis mobile terminal system is to realize streaming media data collection, support real-time collection and streaming of video signals at the fault site, and the software has fault case display, photo and video shooting and uploading , fault information push reminder and other functions. in:
1、远程诊断数据采集系统:利用虚拟仪器集成开发环境Labview进行数据采集软件的开发,通过HTTP协议获取云端服务器故障案例列表数据,采用流式Socket发送实时数据到云端服务器。1. Remote diagnosis data acquisition system: use the virtual instrument integrated development environment Labview to develop data acquisition software, obtain cloud server fault case list data through HTTP protocol, and use streaming socket to send real-time data to cloud server.
远程诊断数据源信号的选择:数控机床在工作中产生的特征信号的种类和数量众多,在远程诊断时,如果对所有的状态信号监测显然是不可行的,所以应该选择最能反映机床特征的信号作为诊断依据,从而达到高效、准确的故障诊断。数据源信号选择的原则,一般能作为特征参数,应具备以下特性:(1)敏感性:特征参量应该最大化的反映机床的工作状态,在机床设备运行状态微弱变化的情况下,特征参数能产生较大的变化,且能客观的反应出机床设备状态;(2)可靠性:特征参量随被测机床的状态变化应尽可能呈现一定的规律,且具有较高的复现性;(3)可行性:特征参量的测量应具有现实可行性,便于被传感器检测。本发明中,结合现有的硬件条件,本系统选择了电流、振动及温度等信号用于监测机床及其电机的工作运行状态。Selection of remote diagnostic data source signals: There are many types and quantities of characteristic signals generated by CNC machine tools during work. In remote diagnosis, it is obviously not feasible to monitor all status signals, so the one that best reflects the characteristics of the machine tool should be selected. The signal is used as the basis for diagnosis, so as to achieve efficient and accurate fault diagnosis. The principle of data source signal selection can generally be used as characteristic parameters, and should have the following characteristics: (1) Sensitivity: The characteristic parameters should reflect the working state of the machine tool to the maximum extent. In the case of slight changes in the operating state of the machine tool, the characteristic parameters can Large changes can be produced, and can objectively reflect the state of the machine tool equipment; (2) Reliability: The characteristic parameters should show a certain law as much as possible with the state change of the machine tool under test, and have high reproducibility; (3) ) Feasibility: The measurement of characteristic parameters should be realistic and feasible, so as to be easily detected by sensors. In the present invention, combined with the existing hardware conditions, the system selects signals such as current, vibration and temperature to monitor the working status of the machine tool and its motor.
本发明中,远程诊断数据采集硬件的选择包括温度传感器、电流传感器、振动传感器、DAQ数据采集卡。In the present invention, the selection of remote diagnostic data acquisition hardware includes temperature sensors, current sensors, vibration sensors, and DAQ data acquisition cards.
本发明中,远程诊断数据采集软件设计,首先是Labview故障案例列表的获取,故障诊断必须针对某一个独立的故障案例,所以在采集数据的过程中也必须针对特定的案例,这就需要获取云端服务器的故障列表,然后现场维修工程师选择对应的故障案例进行数据采集工作。本系统Labview采用HTTP(HyperText Transfer Protocol)协议与云端服务器进行通信来获取故障列表数据。HTTP位于OSI七层网络模型中的应用层,具有简单快速、灵活等优点。利用LabVIEW下的HTTP网络工具包和Socket网络工具包,根据云端服务器提供的接口实现了云端故障列表的获取和传感器数据的实时传输。其次,LabVIEW传感器数据发送前处理,在开始向服务器发送传感器数据之前,必须通知服务器这些数据所对应的故障案例,因此本采集系统采用HTTP协议的GET请求,将故障案例id发送到服务器,服务器就能明白接下来的监测数据所对应的故障案例。最后,Labview发送传感器数据,之前我们是用HTTP 协议和云服务器交换数据,但是HTTP 是无状态的,客户端与服务器每进行一次HTTP操作,就建立一次连接,但是任务结束后就中断连接,达不到高的实时要求。采集的传感器信号是一个连续的信号,显然HTTP 不适合这样的场景,因此,我们需要用到Socket 接口。在网络模型中是应用层与传输层的中间软件抽象层接口,Socke 接口定义了许多网络连接的APIs,使程序员能够很容易用它们来开发基于TCP/IP 网络上的应用程序。In the present invention, the remote diagnosis data acquisition software design is firstly the acquisition of the Labview failure case list, and the failure diagnosis must be aimed at a certain independent failure case, so it must also be aimed at a specific case in the process of collecting data, which requires the acquisition of cloud The fault list of the server, and then the on-site maintenance engineer selects the corresponding fault case for data collection. The Labview of this system uses the HTTP (HyperText Transfer Protocol) protocol to communicate with the cloud server to obtain the fault list data. HTTP is located in the application layer of the OSI seven-layer network model, and has the advantages of simplicity, speed, and flexibility. Using the HTTP network toolkit and Socket network toolkit under LabVIEW, according to the interface provided by the cloud server, the acquisition of the cloud fault list and the real-time transmission of sensor data are realized. Secondly, LabVIEW sensor data is processed before sending sensor data to the server. Before sending sensor data to the server, the server must be notified of the fault cases corresponding to these data. Therefore, this acquisition system uses the GET request of the HTTP protocol to send the fault case id to the server, and the server will Be able to understand the fault cases corresponding to the following monitoring data. Finally, Labview sends the sensor data. We used the HTTP protocol to exchange data with the cloud server before, but HTTP is stateless. Every time the client and server perform an HTTP operation, a connection is established, but the connection is interrupted after the task is over. Less than high real-time requirements. The collected sensor signal is a continuous signal, obviously HTTP is not suitable for such a scene, so we need to use the Socket interface. In the network model, it is the interface of the middle software abstraction layer between the application layer and the transport layer. The Socket interface defines a lot of network connection APIs, so that programmers can easily use them to develop applications on the TCP/IP network.
2、远程诊断云端服务器系统:需满足功能需求和性能需求,其中功能需求包括:故障案例管理、故障相关图片、视频、文件上传分享、实时传感器数据、实时交流。性能需求包括:实时性、开放性、可扩展性。2. Remote diagnosis cloud server system: It needs to meet the functional requirements and performance requirements. The functional requirements include: fault case management, fault-related pictures, videos, file upload and sharing, real-time sensor data, and real-time communication. Performance requirements include: real-time, openness, and scalability.
本发明中远程诊断云端服务器系统采用B/S架构,为了降低UI层、逻辑层和数据层三者之间的耦合度,云服务器系统采用模型-视图-控制器(Model-View-Controller)设计模式,总体架构如图3所示。In the present invention, the remote diagnosis cloud server system adopts B/S architecture. In order to reduce the coupling degree between the UI layer, logic layer and data layer, the cloud server system adopts Model-View-Controller (Model-View-Controller) design mode, the overall architecture is shown in Figure 3.
在数据层,我们使用Mongoose 框架来操作MongoDB 数据库。Mongoose 是一个将JavaScript 对象与数据库产生关系的一个框架,可以用于连接Node.js 与MongoDB。In the data layer, we use the Mongoose framework to operate the MongoDB database. Mongoose is a framework for creating relationships between JavaScript objects and databases, and can be used to connect Node.js and MongoDB.
基于Node.js 的云服务器的前端的逻辑和页面效果主要采用HTML5+CSS3+Bootstrap+AngularJS +Jquery+WebSocket 来实现。HTML+CSS 完成页面的排版,WebSocket 完成实时数据的传输,AngularJS+Jquery 用于页面数据的动态绑定,采用Ajax技术来保证用户交互的及时响应,这样就能够达到良好的用户交互效果。The front-end logic and page effects of the Node.js-based cloud server are mainly realized by HTML5+CSS3+Bootstrap+AngularJS+Jquery+WebSocket. HTML+CSS completes page typesetting, WebSocket completes real-time data transmission, AngularJS+Jquery is used for dynamic binding of page data, and Ajax technology is used to ensure timely response to user interaction, so as to achieve good user interaction effect.
云端服务器的后台采用基于Node.js 的网页框架Express。Express 框架为我们做了很多请求解析的底层工作,这样我们就可以把注意力集中到业务逻辑的编码上,提高开发的效率。Express 框架同样也是基于MVC(Model-View-Controller)设计模式,而且支持符合RESTful 风格的Web 应用和路由管理。The background of the cloud server adopts Express, a web framework based on Node.js. The Express framework does a lot of underlying work for us in request parsing, so that we can focus on the coding of business logic and improve the efficiency of development. The Express framework is also based on the MVC (Model-View-Controller) design pattern, and supports RESTful-style Web applications and routing management.
3. 该远程诊断视频监控流媒体系统采用实时方式,即所谓的流媒体技术,媒体文件数据是以流的形式进行传输,流数据缓存在客户端内存中,然后实时的播放流数据,实现了边下载边播放的效果。在数控机床远程维修系统中,为了让维修专家能够实时地远程指导维修过程,本系统采用流媒体技术,采集故障现场的音、视频数据并将其推送到服务器,网页前端就可以拉取实时的音、视频数据。3. The remote diagnosis video monitoring streaming media system adopts real-time mode, which is the so-called streaming media technology. The media file data is transmitted in the form of streaming, and the streaming data is cached in the client memory, and then the streaming data is played in real time, realizing The effect of playing while downloading. In the remote maintenance system of CNC machine tools, in order to allow maintenance experts to remotely guide the maintenance process in real time, the system uses streaming media technology to collect audio and video data at the fault site and push them to the server, and the front end of the web page can pull real-time Audio and video data.
流媒体系统的架构设计,考虑以下场景:维修人员在机床故障现场维修,通过摄像头和麦克风,把故障现场的音视频信息输出到网络上,多位机床维修专家在各地通过互联网实时观看维修过程。这里存在几个关键点:故障现场的音视频数据采集、流媒体服务器端的流传输和远程专家播放端的音视频获取。The architecture design of the streaming media system considers the following scenarios: maintenance personnel repair at the machine tool failure site, output the audio and video information of the failure site to the network through the camera and microphone, and many machine tool maintenance experts watch the maintenance process in real time through the Internet in various places. There are several key points here: audio and video data collection at the fault site, streaming transmission at the streaming media server, and audio and video acquisition at the playback end of the remote expert.
(1)音视频数据采集,首先必须采集故障现场机床的声音和图像,就是所谓的音视频采集;采集后的音视频数据需要转换成字节码、混合并压缩,最后封装成某种音视频格式,就是所谓的音视频压缩编码;编码压缩后的音视频数据,还不能直接在网络传输,需要转换成某种码流如RTMP,然后推流到流媒体服务器。(1) Audio and video data collection, first of all, the sound and image of the machine tool at the fault site must be collected, which is the so-called audio and video collection; the collected audio and video data needs to be converted into byte codes, mixed and compressed, and finally packaged into some kind of audio and video The format is the so-called audio and video compression coding; the encoded and compressed audio and video data cannot be directly transmitted on the network, and needs to be converted into some kind of code stream such as RTMP, and then pushed to the streaming media server.
(2)流媒体服务器端的流传输,把维修现场的音视频流分发传输给所有观看者。(2) The stream transmission on the streaming media server side distributes and transmits the audio and video streams on the maintenance site to all viewers.
(3)播放端的流媒体数据获取,远程专家获取流媒体服务器的流媒体数据,然后对流进行解析解码播放。(3) Acquisition of streaming media data at the playback end, the remote expert obtains the streaming media data of the streaming media server, and then parses, decodes and plays the stream.
因此,根据以上几个关键点分析,流媒体系统的关键流程如图4所示。Therefore, according to the analysis of the above key points, the key flow of the streaming media system is shown in Figure 4.
首先,远程诊断流媒体系统传输协议的选择,要实现媒体流数据在各端之间传递,各个端上必须遵守相关的应用层协议。流媒体传输协议作为流媒体系统中的关键组成部分,在流媒体系统中起着不可或缺的作用。目前,常见的流媒体实时传输的协议有HTTP(HyperText Transfer Protocol)-FLV 协议、RTMP(Real Time Messaging Protocol)协议和HLS(HTTP Live Streaming)协议。First of all, the selection of the transmission protocol of the remote diagnosis streaming media system, in order to realize the transmission of media stream data between each end, each end must abide by the relevant application layer protocol. As a key component of the streaming media system, the streaming media transmission protocol plays an indispensable role in the streaming media system. Currently, the common streaming media real-time transmission protocols include HTTP (HyperText Transfer Protocol)-FLV protocol, RTMP (Real Time Messaging Protocol) protocol and HLS (HTTP Live Streaming) protocol.
其次,远程诊断视频监控流媒体系统的服务器,流媒体服务器为使用者提供了音视频流数据分发平台,它主要负责接收流媒体数据并缓存在内存中供其他终端拉取流媒体数据。流媒体服务器实现了对流媒体数据的接收、缓存、中转和传输等功能。典型的流媒体服务器有SRS、CRTMP、nginx-rtmp、Red5、FMS等。通过比较,在本系统中我们选择性能优越且稳定性良好的Nginx-RTMP流媒体服务器。流媒体服务器的部署,关键的步骤有:下载安装nginx,下载安装Nginx的扩展rtmp模块,安装完成之后,我们在终端输入查看nginx版本号的命令,配置RTMP模块。Secondly, the server of the remote diagnosis video surveillance streaming media system, the streaming media server provides users with an audio and video streaming data distribution platform, it is mainly responsible for receiving streaming media data and buffering it in memory for other terminals to pull streaming media data. The streaming media server implements functions such as receiving, caching, transferring and transmitting streaming media data. Typical streaming media servers include SRS, CRTMP, nginx-rtmp, Red5, FMS, etc. By comparison, in this system we choose the Nginx-RTMP streaming media server with superior performance and good stability. The key steps for the deployment of the streaming media server are: download and install nginx, download and install the extended rtmp module of Nginx, after the installation is complete, we enter the command to check the version number of nginx in the terminal, and configure the RTMP module.
最后,实现远程诊断网页前端播放,在前端网页的播放器上,我们选择Video.js。Video.js是一个网页播放器类库,它支持通过HTML5播放视频,同时在不支持HTML5对情况下,它会自动切换到Flash播。使用Viedeo.js播放RTMP协议的视频流非常的简单,我们只要指定其视频地址和播放器的大小及位置就可以轻松的实现获取服务器的视频流。Finally, realize the front-end playback of the remote diagnosis webpage. On the player of the front-end webpage, we choose Video.js. Video.js is a web player class library that supports playing video through HTML5, and it will automatically switch to Flash playback if HTML5 is not supported. It is very simple to use Viedeo.js to play the video stream of RTMP protocol. We only need to specify its video address and the size and position of the player to easily obtain the video stream of the server.
4. 远程诊断移动终端系统,在iOS移动终端上开发设计了远程诊断客户端软件,该软件支持故障现场视频信号的实时采集和推流,同时该软件具有故障案例展示、照片和视频拍摄及上传、故障信息推送提醒等功能。4. Remote diagnosis mobile terminal system, developed and designed remote diagnosis client software on the iOS mobile terminal, the software supports real-time collection and streaming of video signals at the fault site, and the software has fault case display, photo and video shooting and uploading , fault information push reminder and other functions.
为了降低软件内各个逻辑层次的耦合性,本终端软件采用MVC(Model-View-Controller)架构,整个终端软件大体可分为5 个部分,分别是界面UI 层、控制层、数据层、网络层和工具层。具体架构如图5所示。In order to reduce the coupling of each logical level in the software, the terminal software adopts the MVC (Model-View-Controller) architecture. The entire terminal software can be roughly divided into five parts, namely the interface UI layer, control layer, data layer, and network layer. and tool layers. The specific architecture is shown in Figure 5.
数据层负责数据模型定义和数据持久化的工作,针对不同的数据类型和特性,我们需要选择合适的方式进行存储,并且提供给外界合适的接口来存储或提取数据。The data layer is responsible for data model definition and data persistence. For different data types and characteristics, we need to choose an appropriate way to store and provide an appropriate interface to the outside world to store or extract data.
界面UI 层主要负责展示各种界面,是数据的表达者。这个层在设计的时候需要注意尽量把数据全面美观的体现出来,并且要适配不同尺寸的设备。Interface The UI layer is mainly responsible for displaying various interfaces and is the expresser of data. When designing this layer, attention should be paid to reflect the data as comprehensively and beautifully as possible, and to adapt to devices of different sizes.
控制层是整个终端软件设计的核心,它主要负责控制其他各层之间的协调工作以及事件控制。首先,当事件发生时(如用户点击),由它来控制向数据层拿取相应数据或使用网络层发起请求,获得数据后,由它把数据交给界面层显示。可以说,控制层起到数据流的管家角色,控制整个终端软件的数据流。The control layer is the core of the entire terminal software design, and it is mainly responsible for controlling the coordination between other layers and event control. First of all, when an event occurs (such as a user click), it controls to get the corresponding data from the data layer or initiate a request using the network layer. After obtaining the data, it hands the data to the interface layer for display. It can be said that the control layer plays the role of steward of the data flow, controlling the data flow of the entire terminal software.
网络层负责将网络请求、相关业务、数据的处理封装起来并对外界暴露统一的接口,网络层设计的重心在与HTTP 请求的统一管理,和请求参数及结果回调的统一控制与数据解析。The network layer is responsible for encapsulating network requests, related services, and data processing and exposing a unified interface to the outside world. The focus of network layer design is the unified management of HTTP requests, and the unified control and data analysis of request parameters and result callbacks.
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