CN1570795A - Open type on-line monitoring, initial failure prediction and diagnosis system - Google Patents

Abstract

A open type on-line monitoring and early failure prefiguration and diagnosis system, wherein the apparatus operation information acquisition subsystem is front end which is connected with apparatus operation information monitoring subsystem though its inner information acquisition computer or computer network card. The apparatus operation information monitoring subsystem is realized through inter-enterprise local area network, which is divided into local monitoring computer, and inter-enterprise remote monitoring computer both of which realize the network sharing and display of monitoring information through setting their own network cards by use of local network. All functions of the system are realized though computers connected with network.

Description

Open online monitoring and early fault prediction and diagnosis system

technical field

The invention relates to an open online monitoring and early fault prediction and diagnosis system, in particular to an open online monitoring and early fault prediction and diagnosis system combining wired and wireless technologies. It is used in the field of equipment online status monitoring and fault diagnosis.

Background technique

Equipment online status monitoring and fault diagnosis system has gone through several stages of stand-alone, centralized and distributed online monitoring and fault diagnosis. The stand-alone monitoring and diagnosis mode has the advantages of good real-time performance and high reliability, but this method requires a large investment, it is difficult to share information between monitoring and diagnosis systems, and it is not conducive to unified operation and maintenance. When the signal transmission distance is permitted, some systems also adopt the centralized monitoring and diagnosis method of multiple sets of equipment. The centralized monitoring and diagnosis method overcomes some of the shortcomings of the stand-alone monitoring and diagnosis mode, but if there are too many measurement points, the collection and monitoring system is overloaded, resulting in poor real-time collection. If it is necessary to add measuring points, the software and hardware of the acquisition and monitoring system must be adjusted, so this mode has poor scalability.

At present, the structure of the online monitoring and fault diagnosis system generally adopted at home and abroad is: based on the wired local area network, and then use the Internet to collect, share and manage the monitoring information; the diagnosis mode is also mainly focused on the operation process alarm and post-event diagnosis (see [US] ] P.M. Rolls, etc., Monitoring, Diagnosis and Simulation of Combined Cycle Power Plants ---- Abdullah Center (Iberdrola's Center for Monitoring, Diagnostic and Simulation (CMDS) of Combined-Cycle Power Plants), "Equipment Management" (ASSET MANAGEMENT), 2003). During the operation of the equipment, important operating information needs to be monitored, and these operating information must be saved for equipment diagnosis and management. The working steps of the commonly used equipment status monitoring and fault diagnosis system are: 1. Use sensors to collect equipment operation information; 2. Preprocess the operation information; 3. Store the operation information in the monitoring industrial Control computer; 4. Industrial control computer broadcasts to the destination computer that needs this information through the limited local area network (and Internet) within the enterprise; 5. Use these operating information for fault diagnosis. These monitoring and diagnosis systems are based on the Internet for remote access to enterprises. The purpose of this model is to achieve the centralization of enterprise equipment operation information. However, due to the different characteristics of enterprise management models, each enterprise has its own management system and information management rules, and each enterprise has basically established its own equipment monitoring and diagnosis system, so it is difficult to realize this centralized monitoring and diagnosis system. . At the same time, for enterprises that have already established a monitoring and diagnosis system, the realization of such a system is a kind of repeated investment.

Contents of the invention

The purpose of the present invention is to address the shortcomings of the above systems and the limitations of the wired local area network itself, and propose an open online monitoring and early fault prediction and diagnosis system that combines wired and wireless technology, so that it can fully utilize and effectively share the information of each user. and the advantages of functional nodes, forming an open and interactive monitoring and diagnosis network system. At the same time, as one of the nodes for early fault prediction, it combines wavelet analysis with traditional Z-transform-based filters, and uses traditional and modern signal processing. Early fault prediction and diagnosis methods are used for fault prediction and diagnosis.

The present invention is realized through the following technical solutions, including: equipment operation information collection subsystem, equipment operation information monitoring subsystem, and equipment operation state failure prediction and diagnosis subsystem. The equipment operation information subsystem is responsible for the collection of equipment operation information and transmits the collected information to the equipment operation information monitoring subsystem through wired and wireless transmission media; the equipment operation information monitoring subsystem is responsible for the equipment operation information transmitted from the equipment operation information subsystem. The information is preprocessed, and monitoring methods such as waveform, spectrum, trend, and wavelet packet sub-band energy are used for monitoring and effective data storage; the fault prediction and diagnosis subsystem of the equipment operating status is mainly responsible for signal analysis and fault diagnosis of the stored equipment operating information. Foreshadowing, diagnosis.

The equipment operation information collection subsystem is the front-end part of the whole system, and the collection of equipment operation information is finally centralized by the information collection computer (or industrial control computer). The equipment operation information collection subsystem is connected with the equipment operation information monitoring subsystem through the network card installed in the information collection computer (or industrial control computer). The monitoring of equipment operation information is realized through the internal LAN of the enterprise. It can be divided into local monitoring computer and remote monitoring computer inside the enterprise. Since this system is an open monitoring and diagnosis network, all function realization terminals are computers connected to the network (local area network or Internet). It is realized by the network port (network card or Modem) inside each node computer.

The equipment operation information acquisition subsystem consists of the equipment to be monitored, wired/wireless transmission medium sensors, wireless switches, signal preprocessing devices, A/D conversion devices (such as various A/D boards) and industrial control computers. Wired/wireless transmission medium sensors are installed at preset measuring points of the equipment to be monitored. For wired transmission medium sensors, the equipment operation information is transmitted to the signal preprocessing device through the wired transmission mode (signal connection line); for wireless transmission medium sensors, it is through the wireless transmission module and wireless switch that comes with the sensor itself. connected, and then transmit the collected equipment operation information to the signal preprocessing device through the wireless switch. Finally, the signal preprocessing device preprocesses all the received signals and transmits them to the A/D conversion device through the wired interface. The A/D conversion device digitizes the received analog signal (equipment operation information) and collects it by the industrial control computer ,monitor.

The equipment operation information monitoring subsystem is composed of a limited local area network, a wireless local area network, a wireless switch and an industrial control computer for monitoring. The wired LAN and the wireless LAN are connected through a wireless switch, and the industrial control computer for monitoring is connected to the wireless switch through a wired or wireless network card to become each user node of the LAN, so that the sharing and remote monitoring of equipment operation information within the LAN can be realized.

The fault prediction and diagnosis subsystem of equipment operation status is composed of Internet and various analysis and diagnosis nodes within the enterprise. These nodes rely on the current Internet network and are Internet users (personal computers or enterprise-level servers).

The information transmission media of the above three subsystems are the combination of wired and wireless transmission media. When the user enterprise has established a status monitoring and fault diagnosis system, the existing online monitoring and diagnosis system structure of each user (including functional nodes, enterprise and individual user nodes) remains unchanged, and the functions of monitoring, fault prediction, and fault diagnosis are established Node, for industries or enterprises where it is difficult to lay out wired transmission media, the wireless LAN structure mode is used to expand the original system, so that each enterprise can collect information and share data for the target equipment that they want to monitor, and run the equipment for the enterprise Lay the foundation for centralized status management. The information sources of monitoring, fault prediction and fault diagnosis are data files collected and processed by each user’s existing online monitoring and diagnosis system. These data files must be decimal data files or binary data files containing only vibration data. At the same time, the user needs to interactively input the corresponding equipment operation information to the function node, so as to carry out status monitoring, fault prediction and fault diagnosis.

The application objects of the present invention are large-scale rotating and reciprocating mechanical equipment systems, which are generally key equipment in the pillar industries of the national economy such as energy, petrochemical, metallurgy, and electric power. Production stops, and sometimes there are vicious accidents of machine crashes and fatalities, resulting in disastrous consequences.

Since a group of large-scale mechanical equipment is a system, the system itself has one or more sets of characteristic quantities, which are called characteristic signals in the field of signal processing. When the operating state of the equipment occurs or its own characteristics change, the corresponding equipment operating characteristic signal or vibration (process quantity) characteristics will also change accordingly. Therefore, if these characteristic quantities are monitored and diagnosed, the health status evaluation of the unit equipment can be obtained, thereby providing condition-based maintenance for the unit. However, because there are many kinds of equipment or the same equipment operating environment; at the same time, the methods that can be applied to equipment status monitoring and fault diagnosis are also different, and they are often sensitive to certain fault characteristics. Based on the above principles, remote monitoring and fault diagnosis can be realized by applying sensor technology, computer technology, and network technology to the above-mentioned condition monitoring and fault diagnosis. Furthermore, by optimizing and sublimating various monitoring and diagnosis methods, more effective methods can be obtained. Using them can monitor the occurrence, development and deterioration of equipment failures throughout the process, thereby optimizing the utilization of equipment and improving Productivity. In addition, due to the non-uniqueness of monitoring and diagnosis methods, the establishment of an open and interactive monitoring and diagnosis network can maximize the advantages of various institutions and individuals, and improve the accuracy of equipment status monitoring, fault prediction and diagnosis.

The equipment operation information collection subsystem and information monitoring subsystem of the present invention use wireless transmission at places where the limited transmission medium is difficult to reach (or the installation of the wired transmission medium is limited by the equipment or the equipment operating environment, such as inflammable and explosive environments such as gas blower units) data acquisition device.

Each enterprise user can monitor the operation status of key equipment and simple fault diagnosis, as long as it can be realized through the internal wired and wireless LAN of the enterprise. If there are limitations in its own functions or diagnostic methods, the centralized operating data can be sorted into "pure" data files (binary or decimal), and then log in to various professional fault prediction and diagnosis nodes to realize early fault prediction and failure of equipment diagnosis. Among them, other information and operating environment of equipment operation require enterprise users to communicate interactively with node servers, so as to obtain early failure prediction or diagnosis results.

The early fault mentioned in the present invention has two meanings, one is a fault in an early stage, a weak fault or a potential fault; the other is physically speaking, a certain fault is an early stage of another fault.

Compared with the monitoring and diagnosis system in the past and the monitoring and diagnosis system currently being studied, wireless transmission technology is added to the three subsystems of the present invention, that is, the transmission of wireless information is realized through wireless sensors and wireless receiving adapters; meanwhile, compared with the previous systems , this system defines the early failure prediction technology.

The advantages of the present invention are:

1) In view of the limitations of the current state monitoring and fault diagnosis network system, the wireless local area network technology that is rapidly developing and applied in industrial practice is used to introduce the online monitoring and fault diagnosis network system, which breaks through the limitations of the use of wired media, so that the maximum Maximize the role of the monitoring and diagnosis system.

2) In view of the limitation of data collection in fault diagnosis of current condition monitoring, wireless transmission technology is used to expand the application range of monitoring system to a greater extent, and the equipment that could not be monitored before is included in the scope of online monitoring and fault diagnosis.

3) At present, the status monitoring and fault diagnosis systems are generally relatively independent, which greatly restricts the development and function of diagnosis technology. The present invention gives full play to the advantages of each research institution, and develops the Internet-based monitoring and diagnosis system into an open monitoring and diagnosis network system without a central server according to the establishment mode of the Internet, which can not only fully mobilize the enthusiasm of each enterprise, reduce The cost of system planning can also maximize the use of various monitoring and diagnosis methods.

Description of drawings

Fig. 1 overall structure block diagram of the system of the present invention

Fig. 2 is a schematic structural diagram of the combination of the data acquisition subsystem and the state monitoring subsystem of the present invention

Fig. 3 the present invention is based on Internet's open state monitoring and fault prediction, diagnosis structural diagram

Fig. 4 structural schematic diagram of the application embodiment of the present invention

Figure 5 is an implementation example diagram of the wireless data acquisition subsystem

Figure 6 is a diagram of the connection mode between each user computer and the network in the system

Detailed ways

As shown in Figure 1, the present invention includes: equipment operation information collection subsystem, equipment operation information monitoring subsystem and failure prediction and diagnosis subsystem of equipment operation status, equipment operation information collection subsystem is the most front part of the whole system, equipment The operation information collection subsystem is connected to the equipment operation information monitoring subsystem through its internal information collection computer or the network card in the industrial control computer. The monitoring of the equipment operation information monitoring subsystem is realized through the internal LAN of the enterprise. It can be divided into local The monitoring computer and the remote monitoring computer inside the enterprise, both realize the network sharing and display of monitoring information through the local area network set on their own network cards. All the function realization terminals of this system are computers connected to the network, and the operating status of the equipment The connection between the fault prediction and diagnosis subsystem and the other two systems is also realized through the network ports inside the computers of each node.

The equipment operation information subsystem is responsible for the collection of equipment operation information and transmits the collected information to the equipment operation information monitoring subsystem through wired and wireless transmission media; the equipment operation information monitoring subsystem is responsible for the equipment operation information transmitted from the equipment operation information subsystem. The information is preprocessed, and monitoring methods such as waveform, spectrum, trend, and wavelet packet sub-band energy are used for monitoring and effective data storage; the fault prediction and diagnosis subsystem of the equipment operating status is mainly responsible for signal analysis and fault diagnosis of the stored equipment operating information. Foreshadowing, diagnosis.

As shown in Figure 2, the equipment operation information acquisition subsystem consists of the equipment to be monitored, wired/wireless transmission medium sensors, wireless switches, signal preprocessing devices, A/D conversion devices and industrial control computers. The wired/wireless transmission medium sensor is set at the preset measuring point of the equipment to be monitored. For the wired transmission medium sensor, it is connected to the signal preprocessing device through the signal connection line; for the wireless transmission medium sensor, it is through the wireless sensor itself. The transmission module is connected to the wireless switch in a wireless manner, and then transmits the collected equipment operation information to the signal preprocessing device through the wireless switch. The signal preprocessing device is connected with the A/D conversion device through a wired interface, and the A/D conversion device is connected with the industrial control computer.

The equipment operation information monitoring subsystem is composed of a limited local area network, a wireless local area network, a wireless switch and an industrial control computer for monitoring. The wired local area network and the wireless local area network are connected through a wireless switch, and the industrial control computer for monitoring is connected with the wireless switch through a wired or wireless network card to become each user node of the local area network.

As shown in Figure 3, the fault prediction and diagnosis subsystem of equipment operation status is composed of Internet network and various analysis and diagnosis nodes within the enterprise. These nodes rely on the Internet network and are Internet network users, that is, personal computers or enterprise-level servers.

The overall structure diagram of the application example of the system of the present invention is shown in Figure 4. The data acquisition devices of the open remote monitoring and fault prediction and diagnosis system combining wired and wireless are wired transmission medium sensors and wireless transmission medium sensors. The data acquisition process of the wired transmission medium in the traditional system has been very perfect. After each wired sensor collects the signal, it is directly connected with the computer to realize the information collection. For the case of wireless transmission, in this example, the wireless sensors produced by the American Pointsix company (currently mainly including wireless temperature and humidity sensors, etc.) are used, and the collected information is transmitted to the computer by the wireless receiving adapter (the wireless receiving adapter of the American Pointsix company), as shown in the figure 5. After the signal is collected, it is sent to the monitoring computer through a wired or wireless medium, and the monitoring computer is connected to the switch through a wired (or wireless) network card to send the monitoring information to an enterprise-level server that is also connected to the switch. The enterprise-level server is connected to the Internet through a broadband network interface such as ISDN, and transmits equipment operation information to various professional diagnosis servers for status monitoring of equipment operation information, early fault prediction and fault diagnosis. The connection mode between each user computer and the network in the system, as shown in Figure 6, mainly includes wired receiving adapter (using IBM10/100 network card), wireless receiving adapter (using Pointsix wireless receiving adapter), Modem and other network adapters (by each user node selected by itself). The system breaks through the limitations of the use of wired media, so that it can maximize the role of monitoring and diagnosis systems, fully mobilize the enthusiasm of enterprises, reduce system planning costs, and use various monitoring and diagnosis methods to the greatest extent. The work of the system is completely open, and any user with login authority can upload the equipment operation information to realize equipment status monitoring, early fault prediction and fault diagnosis.

Claims (4)

1. An open online monitoring and early failure prediction and diagnosis system, including: equipment operation information collection subsystem, equipment operation information monitoring subsystem and equipment operation state failure prediction and diagnosis subsystem, characterized in that the equipment operation information The acquisition subsystem is the front-end part of the whole system. The equipment operation information acquisition subsystem is connected to the equipment operation information monitoring subsystem through its internal information acquisition computer or the network card in the industrial control computer. The monitoring of the equipment operation information monitoring subsystem is It is realized through the internal LAN of the enterprise. It is divided into a local monitoring computer and a remote monitoring computer within the enterprise. Both of them realize the network sharing and display of monitoring information through the network card set on their own with the help of the LAN. All the functions of this system are realized by terminals. The computer connected to the network, the fault prediction of the equipment running status, and the connection between the diagnostic subsystem and the other two systems are also realized through the network ports inside the computers of each node. The equipment running information subsystem is responsible for collecting equipment running information and The collected information is transmitted to the equipment operation information monitoring subsystem through wired and wireless transmission media. The equipment operation information monitoring subsystem is responsible for preprocessing the equipment operation information transmitted from the equipment operation information subsystem, and using waveform, spectrum, trend, Wavelet packet sub-band energy and other monitoring methods are used for monitoring and effective data storage. The fault prediction and diagnosis subsystem of equipment operation status is mainly responsible for signal analysis, fault prediction and diagnosis of the stored equipment operation information. 2. The open online monitoring and early fault prediction and diagnosis system according to claim 1, characterized in that the equipment operation information collection subsystem consists of equipment to be monitored, wired/wireless transmission medium sensors, wireless receiving adapters, switches, signal The preprocessing device, A/D conversion device and industrial control computer are composed. The wired/wireless transmission medium sensor is set at the preset measuring point of the equipment to be monitored. For the wired transmission medium sensor, it is connected to the signal preprocessing device through a signal connection line; For the wireless transmission medium sensor, it is connected to the wireless switch through the wireless transmission module of the sensor itself, and then connected to the signal preprocessing device through the wireless switch, and the signal preprocessing device is connected to the A/D conversion device through a wired interface , The A/D conversion device is connected with the industrial control computer. 3. The open online monitoring and early fault prediction and diagnosis system according to claim 1, characterized in that the equipment operation information monitoring subsystem consists of a limited local area network, a wireless local area network, a wireless and wired receiving adapter, a switch, and an industrial control system for monitoring Composed of computers, the wired local area network and the wireless local area network are connected through a wireless switch, and the industrial control computer for monitoring is connected with the wireless switch through a wired or wireless network card to become each user node of the local area network. 4. The open online monitoring and early fault prediction and diagnosis system according to claim 1, characterized in that the fault prediction and diagnosis subsystem of equipment operation status is composed of the Internet network and various analysis and diagnosis nodes inside the enterprise, and the inside of the enterprise Each analysis and diagnosis node of the network relies on the Internet network, which is a user of each Internet network, that is, a personal computer or an enterprise-level server.

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