CN117516975A - Unmanned automatic empty box stacking machine detection and fault diagnosis system and method - Google Patents
Unmanned automatic empty box stacking machine detection and fault diagnosis system and method Download PDFInfo
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Abstract
The invention is suitable for the technical field of fault diagnosis, and provides a system and a method for detecting and diagnosing faults of an unmanned automatic empty box stacking machine, wherein the system comprises the following components: a device layer comprising a sensor, an actuator, and a controller; the application layer is used for issuing a task instruction to the automatic empty box stacking machine through the upper computer and detecting the normal operation parameter range of the automatic empty box stacking machine; the task instruction comprises lifting, descending, side shifting, swinging, button locking, supporting, detecting mechanism lifting, vehicle body speed planning and steering angle response of the equipment lifting appliance; and performing fault diagnosis on the task flow by detecting the response and the completed state of the whole vehicle controller to the task of the upper computer and combining parameter information fed back by the sensor to obtain a detection result. The invention detects and diagnoses the devices with different functional layers, classifies and counts the devices according to the equipment types, the system attribution, the task flow and the like in the form of fault information groups, and greatly improves the average fault-free time of the system.
Description
Technical Field
The invention relates to the technical field of fault diagnosis, in particular to a system and a method for detecting and diagnosing faults of an unmanned automatic empty box stacking machine.
Background
The intelligent port is the direction of modern port construction trend and development, and unmanned automatic empty box stacking machine research and development can thoroughly change current manual operation mode, changes the shortcoming that manual driving intensity of labour is big, and skilled workman cultivates the cycle length, and the operating efficiency is low, has irreplaceable meaning to realizing intelligent port comprehensively.
In the traditional manual stacker, if equipment fails, different operation tests are carried out on the stacker equipment according to the experience of field operators, and the equipment is observed and checked in sequence. Such an investigation method has the disadvantages of low efficiency, long time consumption and inaccurate investigation for port production. Therefore, it is desirable to provide an unmanned automatic empty-box stacker detection and fault diagnosis system and method, which aims to solve the above problems.
Disclosure of Invention
Aiming at the defects existing in the prior art, the invention aims to provide an unmanned automatic empty box stacking machine detection and fault diagnosis system and method, which are used for solving the problems existing in the background art.
The invention is realized in such a way that an unmanned automatic empty box stacking machine detection and fault diagnosis system comprises:
a device layer comprising a sensor, an actuator, and a controller;
the application layer is used for issuing a task instruction to the automatic empty box stacking machine through the upper computer and detecting the normal operation parameter range of the automatic empty box stacking machine;
the task instruction comprises lifting, descending, side shifting, swinging, button locking, supporting, detecting mechanism lifting, vehicle body speed planning and steering angle response of the equipment lifting appliance; and performing fault diagnosis on the task flow by detecting the response and the completed state of the whole vehicle controller to the task of the upper computer and combining parameter information fed back by the sensor to obtain a detection result.
As a further scheme of the invention: the sensor comprises two main types of analog quantity output type sensors and field bus type sensors.
As a further scheme of the invention: the actuator comprises a driving frequency converter of a power system and a hydraulic cylinder of a hydraulic system.
As a further scheme of the invention: the controller comprises a whole vehicle controller and an upper computer controller, and the whole vehicle controller and the upper computer controller are communicated through a field bus.
As a further scheme of the invention: according to the influence degree of the faults, the fault diagnosis contents are divided into five grades, namely: alert alerts, severe alerts, particularly severe alerts, emergency incidents, and alert bypasses.
As a further scheme of the invention: the emergency situation is the highest-level fault and can trigger the automatic empty box stacker equipment to stop in an emergency; particularly serious warning is a next-highest level fault, which triggers the automatic empty bin stacking machine to stop.
As a further scheme of the invention: the serious warning can trigger the automatic empty box stacker equipment to stop at a reduced speed; the warning bypass is recorded and displayed information after a background manager passes through a remote instruction bypass; the warning prompt can not trigger the automatic empty box stacking machine to stop, and is used for displaying the warning prompt for background personnel.
As a further scheme of the invention: and carrying out statistical classification in a group mode, distinguishing fault information of different functional types through fault group names, and distinguishing different fault reasons in the same group through group member names.
As a further scheme of the invention: detecting the response of an actuator instruction, the running state and the task flow of a controller by collecting sensor analog quantity signals and communication data; and analyzing the diagnosis result of the control information and the vehicle state operation data.
Compared with the prior art, the invention has the beneficial effects that:
the invention detects and diagnoses the devices with different functional layers, and classifies and counts the devices according to the types of equipment, the attribution of the system, the task flow and the like in the form of fault information groups. Meanwhile, fault information is divided into a plurality of grades according to different fault influence degrees, and fault treatment schemes such as speed reduction operation, emergency stop and the like are implemented according to specific fault grade coping strategies. The management system automatically classifies and diagnoses the reported information of the AECH, and realizes the rapid elimination of faults in a manual intervention mode, thereby greatly improving the average fault-free time of the AECH system.
Drawings
FIG. 1 is a block diagram of a detection and fault diagnosis system according to the present invention.
FIG. 2 is a flow chart of fault diagnosis of the pseudo sensor in the present invention.
FIG. 3 is a flow chart of a sensor fault diagnosis bypass process in the present invention.
FIG. 4 is a fault level diagram of the detection and fault diagnosis in the present invention.
Fig. 5 is a diagram of the cartesian coordinate definition of the automatic empty-box stacker apparatus of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more clear, the present invention will be described in further detail with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Specific implementations of the invention are described in detail below in connection with specific embodiments.
As shown in fig. 1 to 5, an embodiment of the present invention provides an unmanned automatic empty-box stacking machine detection and fault diagnosis system, which includes:
a device layer comprising a sensor, an actuator, and a controller;
the application layer is used for issuing a task instruction to the automatic empty box stacking machine through the upper computer and detecting the normal operation parameter range of the automatic empty box stacking machine;
the task instruction comprises lifting, descending, side shifting, swinging, button locking, supporting, detecting mechanism lifting, vehicle body speed planning and steering angle response of the equipment lifting appliance; and performing fault diagnosis on the task flow by detecting the response and the completed state of the whole vehicle controller to the task of the upper computer and combining parameter information fed back by the sensor to obtain a detection result.
In the embodiment of the invention, the sensor comprises two main types, namely an analog output type sensor and a field bus type sensor; the actuator comprises a driving frequency converter of a power system and a hydraulic cylinder of a hydraulic system; the controller comprises a whole vehicle controller VCU and an upper computer controller, and the whole vehicle controller and the upper computer controller are communicated through a field bus.
In the embodiment of the invention, according to the influence degree of the fault, the fault diagnosis content is divided into five grades, which are respectively: alert alerts (Warning), severe alerts (Critical), particularly severe alerts (E-Critical), emergency emergencies (Emergency), and alert bypasses (Warning-Bypass).
In the embodiment of the invention, the emergency situation is the highest-level fault, mainly external emergency stop input, can trigger the automatic empty-box stacker equipment to stop emergently, and can reset operation only by manually releasing the external emergency stop input; particularly serious warning is a secondary high-level fault, mainly comprising the steps of communication interruption of an internal controller, loss of vehicle positioning information and power energy system fault, wherein the failure level of the level can trigger AECH (automatic empty box stacker) equipment to stop, and the AECH can be reset to run only by manually participating in or remotely operating the AECH to a maintenance point for fault investigation.
In the embodiment of the invention, the fault information content of the level is complex, the aspects of communication among all large modules, hardware body, program response and the like are taken as main aspects, the serious warning can trigger the automatic empty-box stacker equipment to stop in a decelerating way, and the level warning is notable in two main aspects of performing double redundancy on key devices by AECH equipment, and the method comprises the following steps: the BYPASS type and the non-BYPASS type can be used for replacing fault modules by BYPASS according to the characteristics of the double redundancy modules, so that the fault of the BYPASS type can be reset, and AECH equipment can continue to operate; furthermore, the BYPASS type Critical level fault can not be used, and the BYPASS can not be used for resetting the fault, so that personnel are needed to participate in confirmation, or the AECH is remotely operated to a maintenance point for fault detection, so that the operation can be reset. The warning bypass is special, is triggered by detecting AECH (automatic empty box stacker) operation information, and is recorded and displayed by a background manager after a bypass is instructed remotely; the warning prompt can not trigger the automatic empty box stacking machine to stop, and is used for displaying the warning prompt for background personnel.
In the embodiment of the invention, the fault information of different functional classes is classified by the fault group names in a statistical way in the form of groups, and different fault reasons in the same group are distinguished by the group member names. In the embodiment of the invention, the response of an actuator instruction, the running state and the task flow of a controller are detected by collecting sensor analog quantity signals and communication data; and analyzing the diagnosis result of the control information and the vehicle state operation data.
As shown in fig. 1 to 5, in the whole system, the analog quantity sensor adopts 4-20mA to transmit signals because the current type signals have good anti-interference performance in the field operation. Fig. 2 shows a fault diagnosis flow of the analog quantity sensor, taking a hardware fault of the device layer cylinder displacement analog quantity sensor in fig. 1 as an example.
Specifically, the VCU converts the collected 4-20mA current signal into 4000-20000 digital quantity signal, when the digital quantity signal detected by the VCU is always greater than 4000 or always less than 20000, the read signal represents the cylinder position, and if the digital quantity signal detected by the VCU is less than 4000 or greater than 20000, the signal belongs to the error value.
Further, in this embodiment, to prevent the system from false detection and triggering the AECH shutdown, when the VCU reads the wrong value, the fault alarm is triggered after 3 seconds. The fault alarm belongs to a hardware fault group of the oil cylinder displacement sensor and belongs to a Critical level shown in fig. 4.
At present, a CAN bus is generally adopted as a vehicle control bus, and the sensor supporting the CAN bus is selected in the embodiment because the CAN bus has the characteristics of small communication data volume and stable transmission. Specifically, the VCU receives data of the sensor in real time through the CAN receiving functional block, and judges whether the CAN bus device is operating normally or not through the heartbeat signal.
In the application layer task flow, as shown in fig. 1, in this embodiment, the task of forward tilting of the upper computer lifting appliance is taken as an example: specifically, the upper computer issues a lifting appliance forward tilting instruction, the gantry tilts forward 100mm in the X direction of a Cartesian coordinate system as shown in fig. 5, the VCU converts the displacement value of the upper computer into the extension length of the supporting oil cylinder by a triangle formula according to the distance from a fixed point of the gantry supporting oil cylinder to a gantry pitching pivot point and the distance from the gantry supporting fixed point to the gantry pitching point.
Furthermore, the VCU calculates the opening degree of the hydraulic valve through a PID algorithm according to the given displacement value of 4mm and the feedback value of the current displacement sensor to complete the positioning control of the oil cylinder. And (5) reversely pushing the forward tilting displacement of the portal frame by utilizing a triangle formula according to the feedback value of the oil cylinder, and considering that the positioning is finished if the control error range is smaller than 10 mm.
Further, if the positioning task continues for 60 seconds without meeting the control error range, the system considers that the task is completed as failed. And triggering a fault alarm, and stopping the movement of the AECH equipment. Awaiting further processing of the instruction.
As shown in fig. 4, to distinguish the severity of the fault information, the detection and fault diagnosis system classifies the fault information into five classes, and makes the AECH respond differently according to the fault classes of different degrees.
The failure information triggered by the Emergency stop signal triggered by the AECH belongs to the grade of Emergency in fig. 4, and is an artificial slapping vehicle body Emergency stop button, or a remote Emergency stop button, and the input of an external Emergency stop signal triggers a safety module of the VCU. The detection and fault diagnosis system triggers the AECH fault by detecting the signal of the safety module. This level of failure would cause the AECH to stop at a maximum required deceleration of 1.5 m/s.
The failure information of the AECH triggering and the upper computer heartbeat detection disconnection belongs to the E-Critical level in fig. 4, and whether the equipment is on line or not is judged by detecting the data changes of 0 and 1 in a certain period. If the received data is 0 or 1 and the duration exceeds 400ms, a fault off from the upper computer heartbeat detection is triggered, and the fault of the level causes the AECH equipment to stop at a deceleration of 1 m/s.
As shown in fig. 3, a sensor fault diagnosis bypass process flow is taken as an example of a hardware fault of the pull-rope encoder on the left side of the device layer shown in fig. 1 in this embodiment: in the AECH operation process, the VCU collects the height data of the stay cord encoder in real time through the CAN receiving block, and in order to prevent the situation that the stay cord is broken, if the height data of the portal frame is unchanged for 1s in the lifting and descending process or the height data of a certain layer is changed too quickly to exceed 800mm/s, the stay cord encoder is considered to be out of order, and the AECH equipment stops operation. The failure information is a Critical level, and failure of this level causes the AECH to stop at a deceleration of 0.8 m/s.
Furthermore, when a fault of the Critical level occurs, in order to reset the fault as soon as possible, the BYPASS type and the non-BYPASS type are distinguished for the fault of the level at the beginning of design, the BYPASS type can realize remote operation, fault information is eliminated, the reset equipment works, and the non-BYPASS type needs personnel intervention.
In order to achieve the above purpose, the embodiment performs double redundancy design on AECH key sensing devices, such as a pull rope encoder, a steering angle encoder, an oil cylinder displacement sensor and the like.
Preferably, when the upper computer receives the hardware fault of the stay cord encoder reported by the AECH, the fault can be processed by selecting a BYPASS, so that the equipment is reset to normally operate.
Specifically, a hardware fault function of the left side encoder of the BYPASS is selected in the background, when the VCU receives a processing instruction, the height reading of the right side stay cord encoder is given to the variable of the left side stay cord encoder in a program, and portal height data is obtained through calculation. And displaying a Warning-Bypass level fault of the fourth level after the Bypass operation, wherein the fault of the level can enable the AECH to move at a low speed to complete the current task, and prompting a manager to troubleshoot the fault before the next task starts.
The Warning level fault shown in fig. 4 is a fault that exceeds the normal use range of the device. In the present embodiment, the cooling water temperature is high, and the driving motor temperature is high.
Specifically, in this embodiment, the cooling water temperature is about 20-50 degrees at the normal working temperature, and the normal working temperature of the motor is about 20-70 degrees, and the system detects the temperature of the cooling water and the temperature of the driving motor, and when the temperature of the cooling water collected by the sensor exceeds 60 degrees, or the temperature of the driving motor exceeds 80 degrees, the fault level of the level is triggered. The alarm of the level mainly aims at displaying an alarm, does not influence the normal operation of the AECH, and aims at reminding a manager to check and remove faults.
To facilitate statistical management, faults are statistically classified in different codes and groups for human review.
In particular, the specific content of the fault information is represented by numbers 1-1999, 2000-2999, 5000-5999.
Further, the number of 1-99 is used for representing the communication fault between the VCU of the whole vehicle controller and the upper computer; AECH drive system failure is represented by numbers 100-199; the failure of the AECH cooling system is represented by the numbers 200-299; a failure of the AECH hydraulic system is represented by a number from 400 to 499; a failure of the AECH steering system is represented by a number of 500-599; a failure of the AECH security system is represented by a number from 700-799; AECH power system failure is represented by the numbers 1000-1199; the charging system failure of the AECH is represented by the numbers 1200-1299; the failure of the AECH spreader device is represented by the numbers 2000-2199, and the failure of the task layer of the AECH spreader is represented by the numbers 2200-2299; represented by the numeral 5000-5999 is fault information after BYPASS.
The embodiment of the invention also provides a detection and fault diagnosis method of the unmanned automatic empty box stacking machine, which comprises the following steps: issuing a task instruction to the automatic empty box stacking machine through the upper computer, and detecting the normal operation parameter range of the automatic empty box stacking machine; and performing fault diagnosis on the task flow by detecting the response and the completed state of the whole vehicle controller to the task of the upper computer and combining parameter information fed back by the sensor to obtain a detection result.
The foregoing description of the preferred embodiments of the present invention should not be taken as limiting the invention, but rather should be understood to cover all modifications, equivalents, and alternatives falling within the spirit and principles of the invention.
It should be understood that, although the steps in the flowcharts of the embodiments of the present invention are shown in order as indicated by the arrows, these steps are not necessarily performed in order as indicated by the arrows. The steps are not strictly limited to the order of execution unless explicitly recited herein, and the steps may be executed in other orders. Moreover, at least some of the steps in various embodiments may include multiple sub-steps or stages that are not necessarily performed at the same time, but may be performed at different times, nor do the order in which the sub-steps or stages are performed necessarily performed in sequence, but may be performed alternately or alternately with at least a portion of the sub-steps or stages of other steps or other steps.
Other embodiments of the present disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure. This application is intended to cover any adaptations, uses, or adaptations of the disclosure following, in general, the principles of the disclosure and including such departures from the present disclosure as come within known or customary practice within the art to which the disclosure pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.
Claims (10)
1. An unmanned automatic empty-box stacker detection and fault diagnosis system, the system comprising:
a device layer comprising a sensor, an actuator, and a controller;
the application layer is used for issuing a task instruction to the automatic empty box stacking machine through the upper computer and detecting the normal operation parameter range of the automatic empty box stacking machine;
the task instruction comprises lifting, descending, side shifting, swinging, button locking, supporting, detecting mechanism lifting, vehicle body speed planning and steering angle response of the equipment lifting appliance; and performing fault diagnosis on the task flow by detecting the response and the completed state of the whole vehicle controller to the task of the upper computer and combining parameter information fed back by the sensor to obtain a detection result.
2. The unmanned automatic empty-box stacker detection and fault diagnosis system according to claim 1, wherein the sensor comprises two main types, an analog output type sensor and a field bus type sensor.
3. The unmanned automatic empty-box stacker detection and fault diagnosis system according to claim 1, wherein the actuator comprises two types of a driving frequency converter of a power system and a hydraulic cylinder of a hydraulic system.
4. The unmanned automatic empty-box stacker detection and fault diagnosis system according to claim 1, wherein the controller comprises a whole vehicle controller and an upper computer controller, and the whole vehicle controller and the upper computer controller are communicated through a field bus.
5. The unmanned automatic empty-box stacker detection and fault diagnosis system according to claim 1, wherein the fault diagnosis contents are classified into five classes according to the degree of influence of the fault, respectively: alert alerts, severe alerts, particularly severe alerts, emergency incidents, and alert bypasses.
6. The unmanned automatic empty-box stacker detection and fault diagnosis system of claim 5, wherein the emergency is a highest-level fault that triggers an automatic empty-box stacker device to stop emergency; particularly serious warning is a next-highest level fault, which triggers the automatic empty bin stacking machine to stop.
7. The unmanned automatic empty-box stacker detection and fault diagnosis system of claim 5, wherein the severe alert triggers the automatic empty-box stacker apparatus to slow down and stop; the warning bypass is recorded and displayed information after a background manager passes through a remote instruction bypass; the warning prompt can not trigger the automatic empty box stacking machine to stop, and is used for displaying the warning prompt for background personnel.
8. The unmanned automatic empty-box stacker detection and fault diagnosis system according to claim 5, wherein the fault information of different functional classes is statistically classified in the form of groups, and different fault causes in the same group are distinguished by group names.
9. The unmanned automatic empty-box stacker detection and fault diagnosis system according to claim 1, wherein the detection of the response of the actuator command, the running state and the controller task flow is performed by collecting sensor analog signals and communication data; and analyzing the diagnosis result of the control information and the vehicle state operation data.
10. An unmanned automatic empty-box stacker detection and fault diagnosis method applied to the system of claim 1, characterized in that the method comprises the following steps:
issuing a task instruction to the automatic empty box stacking machine through the upper computer, and detecting the normal operation parameter range of the automatic empty box stacking machine;
and performing fault diagnosis on the task flow by detecting the response and the completed state of the whole vehicle controller to the task of the upper computer and combining parameter information fed back by the sensor to obtain a detection result.
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| CN202311611708.6A CN117516975A (en) | 2023-11-29 | 2023-11-29 | Unmanned automatic empty box stacking machine detection and fault diagnosis system and method |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118797293A (en) * | 2024-09-10 | 2024-10-18 | 中工重科智能装备有限责任公司 | A real-time fault monitoring and early warning system for container stackers |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118797293A (en) * | 2024-09-10 | 2024-10-18 | 中工重科智能装备有限责任公司 | A real-time fault monitoring and early warning system for container stackers |
| CN118797293B (en) * | 2024-09-10 | 2024-12-06 | 中工重科智能装备有限责任公司 | Container stacking machine real-time fault monitoring and early warning system |
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