CN116009445A - Remote equipment fault automatic alarm, spot inspection maintenance monitoring system and implementation method - Google Patents
Remote equipment fault automatic alarm, spot inspection maintenance monitoring system and implementation method Download PDFInfo
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- CN116009445A CN116009445A CN202211707343.2A CN202211707343A CN116009445A CN 116009445 A CN116009445 A CN 116009445A CN 202211707343 A CN202211707343 A CN 202211707343A CN 116009445 A CN116009445 A CN 116009445A
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Abstract
The invention relates to a remote equipment fault automatic alarming, spot checking and maintenance monitoring system and an implementation method, wherein a main computer is connected with a wireless communication module I, a monitoring terminal is connected with a plurality of sensors arranged on the monitoring equipment, and the wireless communication module I and the monitoring terminal realize two-phase wireless communication; the wireless communication module I is used for receiving the data signal of the monitoring terminal and transmitting the data signal to the main computer, and transmitting the parameters and instructions issued by the main computer to the monitoring terminal; the main computer is used for managing the data information of the monitoring terminal, issuing operation parameters and operation instructions to the monitoring terminal, and notifying related personnel for maintenance and repair after the failure occurs; the sensor is used for monitoring the running condition of the monitoring equipment and outputting a monitoring data signal to the monitoring terminal. The method can realize the remote monitoring of the real-time running condition of the application equipment, and once the equipment running problem occurs, the method can timely receive alarm information, guide maintenance personnel to take accurate maintenance measures, remove running faults and reduce production loss.
Description
Technical Field
The invention relates to a remote equipment fault automatic alarming and spot checking maintenance monitoring system and an implementation method thereof, belongs to the field of automatic control, and is particularly suitable for application places of unmanned on duty units, machine rooms, automatic/semi-automatic production equipment and other important facilities with faults, automatic remote alarming, repair and daily maintenance, spot checking and maintenance.
Background
With the increasing level of industrial automation, the automatic and semi-automatic equipment gradually replaces the original old manual equipment, and forms an emerging production mode of an automatic operation unit, an unmanned workshop, a digital workshop and the like. In the equipment upgrading and updating process, some original semi-automatic and digital mechanical equipment can be automatically and intelligently upgraded by adding technical means such as an automatic control module, so that the unattended operation effect is achieved. Many devices realize single function upgrading, then many devices are integrated and combined to form the upgrading transformation of the whole production line body, thereby realizing automatic production and unattended production. The upgraded automatic equipment units do not have an autonomous active remote alarm function, and once a certain link fails, the equipment units are not maintained in time, so that the whole wire body is paralyzed and stopped, and the economic loss of a using unit is caused.
If the original preheating kiln and curing kiln of the company only have the functions of large capacity, temperature rise and heat preservation, have no functions of automatically opening and closing the door, transmitting and receiving the door and entering the tray, and have the functions of automatically opening and closing the door, automatically transmitting and receiving the door and entering the tray after automatic upgrading and transformation. The entrance and exit of the filling machine is provided with an electric door opening and closing function, positioning filling can be performed, after upgrading and transformation, a proximity sensor is added at the entrance and exit of the filling machine, automatic induction door opening and closing of incoming materials is realized, and automatic filling is performed after the incoming materials are transmitted to a designated position. The 3 devices are connected through the conveying belt, so that automatic preheating and automatic tray discharging are realized, the automatic tray discharging is sent into the filling machine through the preheating conveying belt, after filling is finished, the whole process that the automatic tray discharging machine is sent into the curing kiln through the curing conveying belt is automated, and an unmanned operation on duty working mode is entered.
However, in actual production operation, once each operation link fails, the operation system is easy to idle, accumulate and collide, and even equipment is damaged when serious. Therefore, the application site needs to be provided with an automatic alarm and spot inspection maintenance monitoring system with remote equipment faults, and once the application site has operation faults, the alarm and maintenance can be timely carried out, so that unnecessary economic losses of a using unit are greatly reduced.
Disclosure of Invention
In view of the defects existing in the prior art, the invention provides a remote equipment fault automatic alarm, spot inspection maintenance monitoring system and an implementation method thereof; the system and the remote host computer perform wireless data transmission in real time through the wireless communication module, monitor the operation of the field device in real time, immediately send out local alarm once the abnormality of the device is found, actively inform the remote host computer, and report the alarm condition of relevant departments such as equipment guarantee, production safety and the like, and timely perform field processing. The monitoring terminal can also monitor the timing point of equipment for checking and maintaining, if the equipment is not maintained in time, actively inform the computer main station of the maintenance request of the field equipment, and avoid potential safety hazards caused by the fact that the maintenance is not in place, thereby ensuring the safe operation of the equipment.
The technical scheme adopted by the invention is as follows: a remote equipment fault automatic alarming, spot inspection and maintenance monitoring system comprises a main computer, a wireless communication module I, a monitoring terminal and a plurality of sensors arranged on the monitoring equipment;
the main computer is connected with a wireless communication module I, the monitoring terminal is connected with a plurality of sensors arranged on the monitoring equipment, and the wireless communication module I and the monitoring terminal realize two-phase wireless communication;
the wireless communication module I is used for receiving the data signal of the monitoring terminal and transmitting the data signal to the main computer, and transmitting the parameters and instructions issued by the main computer to the monitoring terminal;
the main computer is used for managing the data information of the monitoring terminal, issuing operation parameters and operation instructions to the monitoring terminal, and notifying related personnel for maintenance after the failure occurs;
the sensor is used for monitoring the running condition of the monitoring equipment and outputting a monitoring data signal to the monitoring terminal.
A method for realizing a remote equipment fault automatic alarming, spot inspection and maintenance monitoring system includes that monitoring equipment is provided with sensors with corresponding functions at monitoring positions according to monitoring requirements, and a touch control integrated machine of a monitoring terminal collects operation conditions of the monitoring equipment through connecting the sensors; the touch control integrated machine processes, analyzes and collects signals, if running faults are found, an audible and visual alarm of the touch control integrated machine gives out fault alarm, and the audible and visual alarm is in wireless communication with a host computer connected with the wireless communication module I through a wireless communication module II connected with the touch control integrated machine, so that running conditions and fault information of monitoring equipment are transmitted to the host computer, and the host computer informs relevant personnel of field maintenance according to the fault conditions;
the touch control integrated machine of the monitoring terminal stores a spot inspection schedule of the monitoring equipment, and when spot inspection is performed and spot inspection maintenance is not performed, the touch control integrated machine actively prompts a host computer through wireless communication, and the host computer informs relevant personnel of field maintenance according to the spot inspection requirement.
The invention has the beneficial effects that: after the remote equipment fault automatic alarm and spot inspection maintenance monitoring system is put into application, the real-time running condition of the remote monitoring application equipment can be realized, and the real-time production progress can be mastered. The equipment is maintained at regular time, the field faults are reduced, once the equipment running problem occurs, alarm information can be received timely, maintenance personnel are guided to take accurate maintenance measures, the running faults are removed, and the production loss is reduced.
Drawings
FIG. 1 is a system connection block diagram of the present invention;
fig. 2 is a system connection block diagram of an embodiment of the present invention.
Detailed Description
As shown in FIG. 1, the remote equipment fault automatic alarming and spot inspection maintenance monitoring system comprises a main computer, a wireless communication module I, a monitoring terminal and a plurality of sensors arranged on the monitoring equipment; the monitoring terminal comprises a wireless communication module II, a touch control integrated machine, an audible and visual alarm and a terminal power supply;
the main computer is connected with the wireless communication module I, the touch control integrated machine is respectively connected with the wireless communication module II, the audible and visual alarm and a plurality of sensors arranged on the monitoring equipment, the wireless communication module I is in biphase wireless communication with the wireless communication module II, and a terminal power supply provides power for the touch control integrated machine, the wireless communication module II and the audible and visual alarm.
The wireless communication module II is used for receiving the data information issued to the monitoring terminal by the host computer and simultaneously transmitting the data information of the monitoring terminal to the host computer; the touch control integrated machine is a control core of the monitoring terminal and is used for collecting data signals of the received sensor and performing corresponding data management and control; the audible and visual alarm receives the alarm signal of the touch control integrated machine and is used for alarming.
The number of the monitoring terminals is N, the N monitoring terminals are respectively connected with a plurality of sensors on the monitoring equipment monitored by the monitoring terminals, and the host computer realizes two-phase wireless communication with the N monitoring terminals through the wireless communication module I.
The host computer of the system can monitor the running conditions of a plurality of monitoring devices simultaneously through the wireless communication module I.
Example 1: as shown in fig. 2, the system is used for a product pouring production line, and is used for automatically alarming faults and checking and maintaining points of the automatic production line in the whole preheating kiln-pouring-curing process.
The system comprises a monitoring terminal 1, a preheating kiln 2, a preheating conveyor belt 3, a pouring machine 4, a curing conveyor belt 5, a curing kiln 6, a main computer 7, a wireless communication module I8 and a plurality of sensors.
The plurality of sensors are specifically: the preheating kiln exit proximity sensor 2-1, the preheating conveyor belt light diffuse reflection switch sensor 3-1, the pouring machine entrance proximity sensor 4-1, the pouring machine exit proximity sensor 4-2, the curing conveyor belt light diffuse reflection switch sensor 5-1 and the curing kiln entrance proximity sensor 6-1.
The preheating conveyor belt 3 is fixed between the outlet of the preheating kiln 2 and the inlet end of the pouring machine 4, and the curing conveyor belt 5 is fixed between the outlet of the pouring machine 4 and the inlet end of the curing kiln 6.
The preheating kiln exit proximity induction switch sensor 2-1 is fixed at the exit of the preheating kiln 2, acquires a preheating kiln 2 exit door opening signal and is in data connection with the monitoring terminal 1;
the preheating conveyor belt light diffuse reflection switch sensor 3-1 is fixed at the middle position of the preheating conveyor belt 3, and is used for collecting article signals passing through the preheating conveyor belt 3 and connecting with the monitoring terminal 1 in a data manner;
the sensor 4-1 of the proximity inductive switch at the entrance of the filling machine is fixed at the entrance of the filling machine 4, and the door opening signal of the entrance of the filling machine 4 is collected and connected with the monitoring terminal 1 in a data way;
the sensor 4-2 of the proximity inductive switch at the exit of the filling machine is fixed at the exit of the filling machine 4, and the door opening signal at the exit of the filling machine 4 is collected and connected with the monitoring terminal 1 in a data way;
the sensor 5-1 of the light diffuse reflection switch of the curing conveyor belt is fixed in the middle of the curing conveyor belt 5, and the curing conveyor belt 5 is connected with the monitoring terminal 1 through article signals in a data mode;
the approach inductive switch sensor 6-1 at the entrance of the curing kiln is fixed at the entrance of the curing kiln 6. And collecting a door opening signal of an inlet of the curing kiln 6, and connecting the door opening signal with the monitoring terminal 1 in a data manner.
The preheating kiln can hold 60 trays of products, and maintain the temperature in the kiln between 85 ℃ and 95 ℃ and has the functions of automatically conveying the trays and automatically opening and closing cabin doors. Usually, the tray products enter a preheating kiln in advance, and are put into a formal pouring production line after being preheated for 2 hours.
The actual production working process comprises the following steps: the product trays discharged from the preheating kiln are conveyed to the pouring machine through the preheating transmission belt, after the pouring machine finishes automatic resin pouring, the products are discharged from the pouring machine and enter the curing kiln 6 through the curing conveyor belt 5, the resin curing is carried out, the operation time of the whole process is 10 minutes at maximum, and the set production beats of the automatic production line are that one tray of products are circularly transmitted every 10 minutes.
The system work flow is as follows:
1. after the production line formally works, the monitoring terminal 1 collects signals of the approaching induction switch sensor 2-1 of the exit of the preheating kiln according to the preset process time, and starts to time the timer of the approaching induction switch sensor 2-1 of the exit of the preheating kiln. Collecting signals of a preheating kiln exit and entrance proximity inductive switch sensor 2-1 within a set time, clearing a timer of the preheating kiln exit and entrance proximity inductive switch sensor 2-1 by 0, and starting to time a preheating conveyor light diffuse reflection switch sensor 3-1; if the signals of the approaching induction switch sensor 2-1 at the exit and the entrance of the preheating kiln are not collected within the set time, the touch control integrated machine immediately controls the audible and visual alarm to give an alarm locally, and meanwhile, the wireless communication module II is communicated with the host computer 7 connected with the wireless communication module I8, the fault signals of the preheating kiln 2 are actively sent out, and the host computer 7 is informed of field maintenance.
2. After the product pallet moves out of the preheating kiln 2, the preheating conveyor belt 3 automatically carries out pallet conveying, the monitoring terminal 1 collects signals of the preheating conveyor belt light diffuse reflection switch sensor 3-1, the signals of the preheating conveyor belt light diffuse reflection switch sensor 3-1 are collected in a set time, a timer of the preheating conveyor belt light diffuse reflection switch sensor 3-1 is clear 0, and the timer of the approaching induction switch sensor 4-1 at the entrance of the filling machine is started; if the signals of the preheating conveyor belt light diffuse reflection switch sensor 3-1 are not collected within the set time, the touch control integrated machine immediately controls the audible and visual alarm to give an alarm locally, and meanwhile, the wireless communication module II is communicated with the host computer 7 connected with the wireless communication module I8, the fault signals of the preheating conveyor belt 3 are actively sent out, and the host computer 7 is informed of field maintenance.
3. The product tray is automatically transmitted to a pouring machine 4 through a preheating conveyor belt 3, a monitoring terminal 1 collects signals of a proximity inductive switch sensor 4-1 at the entrance of the pouring machine, and when the signals of the proximity inductive switch sensor 4-1 at the entrance of the pouring machine are collected within a set time, a timer of the proximity inductive switch sensor 4-1 at the entrance of the pouring machine is cleared by 0, and the time of the proximity inductive switch sensor 4-2 at the exit of the pouring machine is started; if the signal of the proximity inductive switch sensor 4-1 at the entrance of the filling machine is not acquired within the set time, the touch control integrated machine immediately controls the audible and visual alarm to alarm locally, and meanwhile, the wireless communication module II is communicated with the host computer 7 connected with the wireless communication module I8, the fault signal of the filling machine 4 is actively sent out, and the host computer 7 is informed of field maintenance.
4. After the product tray is automatically poured by the pouring machine 4, the product tray is automatically moved out of the pouring machine 4, and the monitoring terminal 1 collects signals of the approaching induction switch sensor 4-2 at the outlet of the pouring machine. And collecting signals of the approaching induction switch sensor 4-2 at the exit of the pouring machine within a set time, clearing a timer of the approaching induction switch sensor 4-2 at the exit of the pouring machine, and starting to time the light diffuse reflection switch sensor 5-1 of the curing conveyor belt. If the signal of the proximity induction switch sensor 4-2 at the exit of the filling machine is not acquired within the set time, the touch control integrated machine immediately controls the audible and visual alarm to give an alarm locally, and meanwhile, the wireless communication module II is communicated with the host computer 7 connected with the wireless communication module I8, the fault signal of the filling machine 4 is actively sent out, and the host computer 7 is informed of field maintenance.
5. The product tray moves out of the curing conveyor belt 5 of the filling machine 4 to automatically carry out product tray conveying, the monitoring terminal 1 collects signals of the light diffuse reflection switch sensor 5-1 of the curing conveyor belt, the timer of the light diffuse reflection switch sensor 5-1 of the curing conveyor belt is clear 0 when the signals of the light diffuse reflection switch sensor 5-1 of the curing conveyor belt are collected within a set time, and the timer of the approach induction switch sensor 6-1 at the entrance of the curing kiln is started; if the signals of the light diffuse reflection switch sensor 5-1 of the curing conveyor belt are not collected within the set time, the touch control integrated machine immediately controls the audible and visual alarm to give an alarm locally, meanwhile, the wireless communication module II is communicated with the host computer 7 connected with the wireless communication module I8, the fault signals of the curing conveyor belt 5 are actively sent out, and the host computer 7 is informed of field maintenance.
6. The product tray is automatically transmitted to a curing kiln 6 through a curing conveyor belt 5, and a monitoring terminal 1 collects signals of a proximity induction switch sensor 6-1 at the entrance of the curing kiln. And collecting a signal of the proximity inductive switch sensor 6-1 at the entrance of the curing kiln within a set time, clearing a timer of the proximity inductive switch sensor 6-1 at the entrance of the curing kiln by 0, and starting to time the proximity inductive switch sensor 2-1 at the exit of the preheating kiln. If the signal of the proximity induction switch sensor 6-1 at the entrance of the curing kiln is not acquired within the set time, the touch control integrated machine immediately controls the audible and visual alarm to locally alarm, and meanwhile, the wireless communication module II is communicated with the host computer 7 connected with the wireless communication module I8, so that the fault signal of the curing kiln 6 is actively sent out, and the host computer 7 is informed of field maintenance.
The whole process monitoring flow runs through one cycle from preheating to curing, and then is executed in a circulating way until the whole product production process is finished.
The equipment timing point is examined and is maintained the warning function: the monitoring terminal is internally provided with operation parameters such as a point detection time table, a project detection table, a maintenance record and the like of each application device. When the equipment is not subjected to spot inspection maintenance at the time, the task is actively prompted to be not performed, the operation safety of the equipment is ensured, and abnormal conditions are avoided.
Timing and remote control on-off functions: the monitoring terminal can be internally provided with a stored equipment on/off schedule, has a local automatic timing switching equipment function, and can also receive the remote control monitoring terminal of the main computer 7, so that the remote control switching function of the controlled equipment is realized, and the processing of emergency events such as field faults and the like is facilitated.
Claims (4)
1. A remote equipment fault automatic alarm, spot inspection and maintenance monitoring system is characterized in that: the system comprises a main computer, a wireless communication module I, a monitoring terminal and a plurality of sensors arranged on monitoring equipment;
the main computer is connected with a wireless communication module I, the monitoring terminal is connected with a plurality of sensors arranged on the monitoring equipment, and the wireless communication module I and the monitoring terminal realize two-phase wireless communication;
the wireless communication module I is used for receiving the data signal of the monitoring terminal and transmitting the data signal to the main computer, and transmitting the parameters and instructions issued by the main computer to the monitoring terminal;
the main computer is used for managing the data information of the monitoring terminal, issuing operation parameters and operation instructions to the monitoring terminal, and notifying related personnel for maintenance after the failure occurs;
the sensor is used for monitoring the running condition of the monitoring equipment and outputting a monitoring data signal to the monitoring terminal.
2. The remote equipment malfunction automatic alarm, spot check maintenance monitoring system according to claim 1, wherein: the monitoring terminal comprises a wireless communication module II, a touch control integrated machine, an audible and visual alarm and a terminal power supply;
the touch control integrated machine is connected with the wireless communication module II and the audible and visual alarm respectively;
the terminal power supply provides power for the touch control integrated machine, the wireless communication module II and the audible and visual alarm;
the wireless communication module II is used for receiving data information issued to the monitoring terminal by the host computer and sending the data information of the monitoring terminal to the host computer;
the touch control integrated machine is a control core of the monitoring terminal and is used for collecting data signals of the received sensor and performing corresponding data management and control;
and the audible and visual alarm receives an alarm signal of the touch control integrated machine and is used for local alarm.
3. The remote equipment malfunction automatic alarm, spot check maintenance monitoring system according to claim 1, wherein: the monitoring terminals are N, the N monitoring terminals are respectively connected with a plurality of sensors on the monitoring equipment monitored by the monitoring terminals, and the host computer realizes biphase wireless communication with the N monitoring terminals through the wireless communication module I.
4. A method for implementing the remote equipment fault automatic alarm, spot inspection and maintenance monitoring system according to claim 1 or 2, which is characterized in that: the monitoring equipment is provided with sensors with corresponding functions at monitoring positions according to monitoring requirements, and the touch control integrated machine of the monitoring terminal is connected with the sensors to acquire the running condition of the monitoring equipment; the touch control integrated machine processes, analyzes and collects signals, if running faults are found, an audible and visual alarm of the touch control integrated machine gives out fault alarm, and the audible and visual alarm is in wireless communication with a host computer connected with the wireless communication module I through a wireless communication module II connected with the touch control integrated machine, so that running conditions and fault information of monitoring equipment are transmitted to the host computer, and the host computer informs relevant personnel of field maintenance according to the fault conditions;
the touch control integrated machine of the monitoring terminal stores a spot inspection schedule of the monitoring equipment, and when spot inspection is performed and spot inspection maintenance is not performed, the touch control integrated machine actively prompts a host computer through wireless communication, and the host computer informs relevant personnel of field maintenance according to the spot inspection requirement.
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