CN111580484A - Online monitoring and fault analysis system and method for cement production enterprise equipment - Google Patents
Online monitoring and fault analysis system and method for cement production enterprise equipment Download PDFInfo
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- CN111580484A CN111580484A CN202010444133.3A CN202010444133A CN111580484A CN 111580484 A CN111580484 A CN 111580484A CN 202010444133 A CN202010444133 A CN 202010444133A CN 111580484 A CN111580484 A CN 111580484A
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 65
- 239000004568 cement Substances 0.000 title claims abstract description 58
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 55
- 238000004458 analytical method Methods 0.000 title claims abstract description 31
- 238000000034 method Methods 0.000 title claims abstract description 7
- 238000012423 maintenance Methods 0.000 claims abstract description 24
- 230000002159 abnormal effect Effects 0.000 claims abstract description 17
- 238000013500 data storage Methods 0.000 claims abstract description 11
- 238000006073 displacement reaction Methods 0.000 claims description 7
- 239000003245 coal Substances 0.000 claims description 5
- 235000012054 meals Nutrition 0.000 claims description 3
- 238000013480 data collection Methods 0.000 claims 2
- 238000007689 inspection Methods 0.000 abstract description 12
- 239000003638 chemical reducing agent Substances 0.000 description 6
- 239000002994 raw material Substances 0.000 description 4
- 230000005856 abnormality Effects 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007726 management method Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31088—Network communication between supervisor and cell, machine group
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/80—Management or planning
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- Manufacturing & Machinery (AREA)
- Quality & Reliability (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Testing And Monitoring For Control Systems (AREA)
Abstract
The invention discloses a system and a method for online monitoring and fault analysis of cement production enterprise equipment, wherein the system comprises a plurality of sensors for acquiring running state data of each cement production equipment in real time; the data acquisition unit is used for acquiring data acquired by each sensor in real time; the data storage unit is used for storing the data acquired by the data acquisition terminal in real time; and the fault analysis unit is used for analyzing the data stored in the data storage unit in real time and acquiring the fault condition of the cement production equipment with abnormal state. The invention can acquire the fault condition of the equipment in time, provide data support for equipment maintenance and stabilize the equipment performance; through pointedly feeding back the equipment fault condition, unnecessary routing inspection can be reduced, the routing inspection intensity is reduced, the routing inspection cost is reduced, and therefore a maintenance plan can be guided, and the equipment over-repair and under-repair risks are reduced.
Description
Technical Field
The invention relates to the field of cement production, in particular to a system and a method for online monitoring and fault analysis of equipment of a cement production enterprise.
Background
The cement production belongs to typical flow type production, and production equipment of the cement production needs to continuously run for a long time, so that the normal running of the equipment is ensured, existing faults are found in time, and great significance is brought to the improvement of enterprise capacity and the improvement of product quality.
At present, most domestic cement production enterprises adopt a manual inspection mode to monitor the equipment state, namely, the equipment running state is judged through a handheld detector or manual experience, and the mode has the defects that the equipment running state cannot be mastered on line in real time, abnormality cannot be found and early-warning cannot be carried out in time, fault analysis cannot be carried out, and the like.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a system and a method for online monitoring and fault analysis of equipment of a cement production enterprise, and solves the problems that the existing cement production enterprise cannot grasp the running state of the equipment online in real time, cannot find abnormality and give an early warning in time, and cannot perform fault analysis.
The technical scheme adopted by the invention for solving the problems is as follows:
a cement manufacture enterprise equipment on-line monitoring and fault analysis system includes:
the sensors are used for acquiring the running state data of each cement production device in real time;
the data acquisition unit is used for acquiring data acquired by each sensor in real time;
the data storage unit is used for storing the data acquired by the data acquisition terminal in real time;
and the fault analysis unit is used for analyzing the data stored in the data storage unit in real time and acquiring the fault condition of the cement production equipment with abnormal state.
Further, as a preferred technical solution, the sensor includes a temperature sensor, a vibration sensor, a displacement sensor and a rotation speed sensor.
Further, as a preferred technical solution, the data acquisition unit acquires data acquired by each sensor in real time by using a TCP/IP protocol.
Further, as a preferred technical solution, the data storage unit is a MySQL database.
Further, as a preferred technical scheme, the cement production equipment comprises raw material vertical mill equipment, a kiln inlet bucket elevator, a rotary kiln, a kiln head exhaust fan, a kiln tail exhaust fan, cement mill equipment, a high-temperature fan, a circulating fan, coal mill equipment and a grate cooler.
Further, as a preferred technical solution, the system further comprises an alarm prompting unit, which is used for performing alarm prompting on the equipment fault condition analyzed by the fault analysis unit, so that a maintenance person can perform accurate maintenance.
A cement manufacturing enterprise equipment on-line monitoring and fault analysis method comprises the following steps:
step 1: acquiring and collecting running state data of each cement production device in real time;
step 2: storing, applying and analyzing the acquired data in real time;
and step 3: and analyzing the fault aiming at the abnormal state data to acquire the fault condition of the cement production equipment with the abnormal state.
Further, as a preferred technical solution, in the step 1, the operating state data of each cement production facility is acquired by installing a sensor at a monitoring point of each cement production facility.
Further, as a preferred technical solution, in the step 1, data of the sensor is acquired in real time through the data acquisition terminal by using a TCP/IP protocol.
Further, as a preferred technical solution, the method further comprises the following step 4: and alarming and prompting the acquired fault condition of the cement production equipment with abnormal state so as to facilitate maintenance personnel to carry out accurate maintenance.
Compared with the prior art, the invention has the following beneficial effects:
according to the invention, more than one hundred monitoring points are arranged on key equipment in the cement production process, such as 10 kinds of equipment, such as raw material vertical mill equipment, a kiln entering bucket elevator, a rotary kiln and the like, so that the cement production equipment can be accurately monitored on line in real time, state data of the equipment, such as temperature, vibration, displacement and the like, fault analysis is carried out on abnormal data states, the fault condition of the equipment is timely obtained, data support is provided for equipment maintenance and equipment maintenance, and the equipment performance is stabilized; through pointedly feeding back the equipment fault condition, unnecessary routing inspection can be reduced, the routing inspection intensity is reduced, the routing inspection cost is reduced, and therefore a maintenance plan can be guided, and the equipment over-repair and under-repair risks are reduced.
Drawings
FIG. 1 is a block diagram of the system components of the present invention.
Detailed Description
The present invention will be described in further detail with reference to examples and drawings, but the present invention is not limited to these examples.
Example 1
As shown in fig. 1, an on-line monitoring and fault analysis system for equipment of a cement manufacturing enterprise according to a preferred embodiment of the present invention includes:
the sensors are used for acquiring running state data of each cement production device in real time, belong to the existing novel sensors, can be applied to the Internet of things, and realize the state data of the cement production devices, such as temperature, vibration, displacement, rotating speed and other parameter monitoring.
Specifically, the present embodiment can perform online monitoring on the following ten kinds of devices, and perform fine monitoring on different components and parts of the devices to obtain status data of the devices, where the detailed monitoring is as follows:
1. raw meal vertical mill equipment monitoring
The online monitoring of a main motor, a main speed reducer and a powder selecting speed reducer of the raw material vertical mill is realized, 18 monitoring points are provided, and the specific monitoring details are shown in table 1:
TABLE 1 raw meal vertical mill equipment monitoring details
2. Bucket elevator for entering kiln
The realization is to the online monitoring of the motor, speed reducer, sprocket of income kiln bucket elevator, totally 8 monitoring points, and specific monitoring details are shown in table 2:
TABLE 2 bucket elevator monitoring details
3. Rotary kiln
The online monitoring of the motor, the speed reducer and the pinion of the rotary kiln is realized, 17 monitoring points are provided, and the specific monitoring details are shown in table 3:
TABLE 3 monitoring particulars of the rotary kiln
4. Kiln head exhaust fan
The on-line monitoring of the motor and the fan of the kiln head exhaust fan is realized, the total number of the monitoring points is 7, and the specific monitoring details are shown in the table 4:
TABLE 4 kiln head exhaust fan monitoring particulars
5. Kiln tail exhaust fan
The on-line monitoring of the motor and the fan of the kiln head exhaust fan is realized, the total number of the monitoring points is 7, and the specific monitoring details are shown in the table 5:
TABLE 5 kiln exhaust fan monitoring particulars
6. Cement mill
The online monitoring of an oil station, a motor, a speed reducer and a pinion of the cement mill is realized, 16 monitoring points are provided, and the specific monitoring details are shown in table 6:
TABLE 6 Cement mill equipment monitoring particulars
7. High-temperature fan
The online monitoring of an oil station, a motor and a fan of the cement mill is realized, 9 monitoring points are provided, and the specific monitoring details are shown in table 7:
TABLE 7 high-temp. Fan monitoring details
8. Circulating fan
The oil station, the motor and the fan of the circulating fan are monitored on line, 9 monitoring points are used, and the specific monitoring details are shown in table 8:
TABLE 8 circulating fan monitoring details
9. Coal mill
The online monitoring of the motor, the speed reducer and the pinion of the coal mill is realized, the total number of the monitoring points is 14, and the specific monitoring details are shown in a table 9:
TABLE 9 coal mill equipment monitoring details
10. Grate cooler
The online monitoring of the motor, the fan and the clinker crusher of the grate cooler mill is realized, 10 monitoring points are provided, and the specific monitoring details are shown in table 10:
table 10 grate cooler monitoring details
The present embodiment further includes a data acquisition unit, and after status data of the above-mentioned device is acquired through a temperature sensor, a vibration sensor, a displacement sensor, a speed sensor, and the like, the data acquisition unit (also called a data acquisition terminal) acquires data acquired by each sensor in real time, and of course, some transmission protocols, such as a TCP/IP protocol, may be used here to realize data acquisition.
The embodiment also comprises a data storage unit, also called a database, which is used for storing the data acquired by the data acquisition terminal in real time, and the data can be stored, applied and analyzed in real time by relying on the basic backbone network of the cement manufacturing enterprise and adopting communication protocols such as Http/MQTT and the like. The data storage unit of this embodiment preferably uses a MySQL database, which is a relational database management system and stores data in different tables, rather than putting all data in one large library, which increases speed and flexibility.
The embodiment further comprises a fault analysis unit, wherein the fault analysis is mainly to analyze the data stored in the data storage unit in real time to acquire the fault condition of the cement production equipment with abnormal state. Taking the kiln head exhaust fan as an example, under normal conditions, the vibration and temperature values of the motor and the fan can be maintained in a normal range, once the vibration and temperature of the motor and the fan are detected by the sensor to be in an abnormal state, the abnormal state of the motor and the fan can be judged, the equipment possibly breaks down, and at the moment, corresponding maintainers can be arranged to carry out targeted maintenance on the kiln head exhaust fan to find out the place of the fault. Similarly, the fault analysis of other devices adopts the same mode.
In order to better feed back the equipment fault to the overhaul site or the inspection site, the embodiment further comprises an alarm prompting unit for giving an alarm prompt on the equipment fault condition obtained by analyzing the fault analyzing unit, so that a maintainer can perform accurate maintenance. Or the fault analysis unit feeds back the equipment fault condition to the control center, and the control center distributes the equipment fault condition to corresponding maintainers, so that the fault maintenance is realized quickly and accurately.
By adopting the structure, more than one hundred monitoring points are arranged on key equipment in the cement production process, such as 10 kinds of equipment, such as raw material vertical mill equipment, a kiln entering bucket elevator, a rotary kiln and the like, so that the cement production equipment can be monitored on line accurately in real time, state data of the equipment, such as temperature, vibration, displacement and the like, can be obtained, fault analysis is carried out on abnormal data states, the fault condition of the equipment is obtained in time, data support is provided for equipment maintenance and equipment maintenance, and the equipment performance is stabilized; through pointedly feeding back the equipment fault condition, unnecessary routing inspection can be reduced, the routing inspection intensity is reduced, the routing inspection cost is reduced, and therefore a maintenance plan can be guided, and the equipment over-repair and under-repair risks are reduced.
The implementation provides an online monitoring and fault analysis method for equipment of a cement production enterprise, which specifically comprises the following steps:
step 1: acquiring and collecting running state data of each cement production device in real time, specifically, acquiring state data of the devices such as temperature, vibration, displacement and the like by installing sensors at key positions of each cement production device;
step 2: the acquired data is stored, applied and analyzed in real time by means of a basic backbone network of a production enterprise and by adopting communication protocols such as Http/MQTT and the like;
and step 3: and fault analysis is carried out on the abnormal state data, the fault condition of the cement production equipment with the abnormal state is obtained, and data support is provided for equipment maintenance.
In order to better feed back the equipment fault to a maintenance place or an inspection place, the obtained fault condition of the cement production equipment with abnormal state can be subjected to alarm prompt, so that maintenance personnel can perform accurate maintenance; or the equipment fault condition is fed back to the control center, and the control center distributes the equipment fault condition to corresponding maintainers, so that the fault maintenance is realized quickly and accurately.
As described above, the present invention can be preferably realized.
The foregoing is only a preferred embodiment of the present invention, and the present invention is not limited thereto in any way, and any simple modification, equivalent replacement and improvement made to the above embodiment within the spirit and principle of the present invention still fall within the protection scope of the present invention.
Claims (10)
1. The utility model provides a cement manufacture enterprise equipment on-line monitoring and failure analysis system which characterized in that includes:
the sensors are used for acquiring the running state data of each cement production device in real time;
the data acquisition unit is used for acquiring data acquired by each sensor in real time;
the data storage unit is used for storing the data acquired by the data acquisition terminal in real time;
and the fault analysis unit is used for analyzing the data stored in the data storage unit in real time and acquiring the fault condition of the cement production equipment with abnormal state.
2. The cement manufacturing enterprise equipment on-line monitoring and fault analysis system of claim 1, wherein the sensors comprise a temperature sensor, a vibration sensor, a displacement sensor and a rotation speed sensor.
3. The system for on-line monitoring and fault analysis of cement manufacturing enterprise equipment according to claim 1, wherein said data collection unit collects data obtained by each sensor in real time using TCP/IP protocol.
4. The system of claim 1, wherein the data storage unit is a MySQL database.
5. The system of claim 1, wherein the cement production equipment comprises raw meal vertical mill equipment, hopper elevator entering the kiln, rotary kiln, kiln head exhaust fan, kiln tail exhaust fan, cement mill equipment, high temperature fan, circulating fan, coal mill equipment and grate cooler.
6. The cement manufacturing enterprise equipment on-line monitoring and fault analysis system according to claim 1, further comprising an alarm prompting unit for giving an alarm prompt for equipment fault conditions analyzed by the fault analysis unit so that maintenance personnel can perform accurate maintenance.
7. A cement manufacturing enterprise equipment on-line monitoring and fault analysis method is characterized by comprising the following steps:
step 1: acquiring and collecting running state data of each cement production device in real time;
step 2: storing, applying and analyzing the acquired data in real time;
and step 3: and analyzing the fault aiming at the abnormal state data to acquire the fault condition of the cement production equipment with the abnormal state.
8. The on-line monitoring and fault analysis method for cement manufacturing enterprise equipment according to claim 7, wherein in the step 1, the operating state data of each cement manufacturing equipment is obtained by installing a sensor at the monitoring point of each cement manufacturing equipment.
9. The method for on-line monitoring and fault analysis of cement manufacturing enterprise equipment according to claim 8, wherein in step 1, data of the sensor is collected in real time through a data collection terminal by using TCP/IP protocol.
10. The cement manufacturing enterprise equipment on-line monitoring and fault analysis method according to claim 7, further comprising the step 4: and alarming and prompting the acquired fault condition of the cement production equipment with abnormal state so as to facilitate maintenance personnel to carry out accurate maintenance.
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| CN202010444133.3A CN111580484A (en) | 2020-05-22 | 2020-05-22 | Online monitoring and fault analysis system and method for cement production enterprise equipment |
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| CN114550336A (en) * | 2022-04-26 | 2022-05-27 | 深圳丰尚智慧农牧科技有限公司 | Equipment inspection method and device, computer equipment and storage medium |
| CN116863556A (en) * | 2023-05-31 | 2023-10-10 | 北京信息职业技术学院 | Industrial field short-distance data transmission system and inspection method |
| CN120315389A (en) * | 2025-04-15 | 2025-07-15 | 平泉冀东水泥有限责任公司 | A cement production line fault monitoring system and method |
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