An industrial predictive maintenance data acquisition system

Abstract

The present invention discloses an industrial preventive maintenance data acquisition system, which belongs to the field of data acquisition and processing technology. In the system, an external battery is connected to a main controller module, a 1.8V power conversion module and a 3.3V power conversion module respectively through a battery interface module in the system, and provides working power for an analog-to-digital converter and a communication module after conversion. The vibration sensor transmits the collected machine vibration frequency response information to the analog-to-digital converter, which is transmitted to the main controller module after processing, and then transmitted to the external industrial gateway by the communication module. The query command of the industrial gateway for the machine status is transmitted to the main controller module through the communication module, and the main controller module obtains the vibration frequency response information of the machine equipment according to the command and feeds it back to the industrial gateway. The present invention can intelligently, quickly and continuously collect and process the machine operation status data, so that technicians can grasp the operation status of the machine in advance to prevent and control machine failures.

Description

Technical Field

[0001] The invention belongs to the technical field of data collection and processing, and in particular to an industrial predictive maintenance data collection system. Background Art

[0002] Predictive Maintenance (PdM) is condition-based maintenance. When the machine is running, it conducts regular (or continuous) condition monitoring and fault diagnosis on its main (or required) parts to determine the equipment's condition and predict the future development trend of the equipment's condition. Based on the equipment's condition development trend and possible failure modes, a predictive maintenance plan is formulated in advance to determine the time, content, method, and necessary technical and material support for the machine's repair.

[0003] In the process of predictive maintenance, data collection and processing of machine operating status are the key to the predictive maintenance system. How to intelligently, continuously and quickly collect data during the machine operation process has become a difficult problem faced by machine operation and maintenance personnel and machine production line designers. Summary of the invention

[0004] The main technical problem solved by the present invention is to provide an industrial predictive maintenance data acquisition system to intelligently, quickly and continuously collect and process the operating status data of machine equipment, predict failures during machine operation, and provide early warning to machine operators, thereby controlling the maintenance cost of the machine and extending the service life of the machine.

[0005] In order to achieve the above-mentioned purpose, a technical solution adopted by the present invention is: to provide an industrial preventive maintenance data acquisition system, which is designed on a printed circuit board and is characterized in that it includes: a battery interface module, which is a channel for an external battery to access the industrial preventive maintenance data acquisition system; a main controller module, which maintains the stable operation of the industrial preventive maintenance data acquisition system, and the main controller module regulates the transmission of the internal current signal of the industrial preventive maintenance data acquisition system. The main controller module receives an external industrial gateway query command, and the main controller module transmits the received vibration state related data of the external machine equipment of the industrial preventive maintenance data acquisition system to the external industrial gateway on a regular basis or according to the query command, and the main controller module is electrically connected to the battery interface module to obtain a working power supply; a 1.8V power conversion module, which receives a first control signal from the main controller module and a current transmitted from the battery interface module, and then the 1.8V power conversion module converts the battery voltage into 1.8V DC according to the first control signal; a 3.3V power conversion module, which receives a second control signal from the main controller module and a current transmitted from the battery interface module, and then the 3.3V power conversion module converts the battery voltage into 1.8V DC according to the second control signal. The control signal converts the battery voltage into 3.3V direct current; a vibration sensor, which detects and collects the vibration state related data of the external machine equipment of the industrial preventive maintenance data acquisition system in real time, and then the vibration sensor converts the vibration state related data of the external machine equipment of the industrial preventive maintenance data acquisition system into an analog signal; an analog-to-digital converter, which receives the analog signal and converts the analog signal into a digital signal, and then the analog-to-digital converter transmits the digital signal to the main controller module through the I2S interface, and the analog-to-digital converter is electrically connected to the 1.8V power conversion module and the 3.3V power conversion module respectively to obtain 1.8V and 3.3V working power supplies; and a communication module, which is a channel for transmitting external industrial gateway query commands and external machine equipment vibration state related data of the industrial preventive maintenance data acquisition system between the industrial preventive maintenance data acquisition system and the external industrial gateway, the communication module is connected to the main controller module and the external industrial gateway respectively to realize the transmission of external industrial gateway query commands and external machine equipment vibration state related data of the industrial preventive maintenance data acquisition system between the main controller module and the external industrial gateway, and the communication module is electrically connected to the 3.3V power conversion module to obtain a 3.3V working power supply. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 This is a schematic diagram of the structural framework of an industrial predictive maintenance data acquisition system of the present invention;

[0007] Attached Figure 1The accessories are marked as follows: 1-battery interface module, 2-main controller module, 3-1.8V power conversion module, 4-3.3V power conversion module, 5-analog-to-digital converter, 6-communication module, 7-vibration sensor;

[0008] Figure 2 This is a front structural diagram of a printed circuit board of an industrial predictive maintenance data acquisition system of the present invention;

[0009] Figure 3 This is a back structural diagram of a printed circuit board of an industrial predictive maintenance data acquisition system of the present invention. DETAILED DESCRIPTION

[0010] The preferred embodiments of the present invention are described in detail below in conjunction with the accompanying drawings so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the protection scope of the present invention.

[0011] It should be noted that the terms "first" and "second" in the claims and the specification in the present application document are only used to distinguish similar objects and do not have to be understood as describing a specific order or sequence.

[0012] The principle of the present invention is that during the operation of industrial machinery and equipment, the vibration condition of the machine can reflect whether the equipment is operating normally. If a machine fails, the relevant data of its vibration state will be different from the data of the machine in the normal state. Therefore, a vibration sensor can be used to process the relevant data of the vibration state of the machinery and equipment during operation (such as vibration frequency response data information) and then feed it back to the technicians, so that the relevant technicians can judge and understand the status of the machinery and equipment, and thus perform better operation and maintenance on it.

[0013] The present invention is a key component in the industrial predictive maintenance system. It mainly processes the vibration frequency response data information collected in real time and actively transmits it to the industrial gateway. The industrial gateway can transmit it to the machine operation and maintenance technician or machine operation technician through the connected data network channel, so that the relevant technicians can grasp the operating status of the machine equipment in advance. The relevant technicians can also issue a machine equipment status query command to the industrial gateway as needed, and this query command is transmitted to the industrial predictive maintenance data acquisition system of the present invention through the industrial gateway. Then, this system executes the query command to obtain the operating status parameter information of the machine equipment (such as vibration frequency response data information). The present invention generates a response feedback signal of the industrial gateway query command based on the collected machine equipment operating status parameter information and transmits the feedback signal to the industrial gateway, and further feeds back to the relevant technicians.

[0014] Figure 1The figure shows a specific implementation of the structural framework of an industrial predictive maintenance data acquisition system of the present invention. In this specific implementation, the industrial preventive maintenance data acquisition system is designed on a printed circuit board, and the printed circuit board has a double-layer structure. In order to reduce the interference between the two layers of signals, the front line in the printed circuit board is mainly horizontally routed, while the back line is mainly vertically routed. The industrial preventive maintenance data acquisition system mainly includes a battery interface module 1, a main controller module 2, a 1.8V power conversion module 3, a 3.3V power conversion module 4, an analog-to-digital converter 5, a communication module 6 and a vibration sensor 7.

[0015] The battery interface module 1 is a channel for the external battery to access the industrial preventive maintenance data acquisition system, which connects the external battery to the industrial preventive maintenance data acquisition system so that the system can obtain a working power supply. Preferably, the external battery is a 1.6Ah lithium battery with a nominal voltage of 3.6V. This type of battery has a long service life. When it is applied to the system of the present invention, combined with the ultra-low power consumption hardware design and a reasonable wake-up acquisition plan, the battery life can reach more than 2 years.

[0016] The main controller module 2 controls the operation of the entire industrial preventive maintenance data acquisition system. On the one hand, the main controller module 2 maintains its own stable operation, wakes up the system regularly, detects the operating status of the industrial preventive maintenance data acquisition system, and ensures smooth transmission of signals (current and control signals) between modules. On the other hand, the main controller module regulates the internal current signal of the industrial preventive maintenance data acquisition system, the external industrial gateway query command, the main controller module regularly and actively reports to the external industrial gateway the vibration state-related data of the external machine equipment of the industrial preventive maintenance data acquisition system, and the transmission of the response signal of the industrial gateway query command generated by the main controller module according to the external industrial gateway query command. The content of the response signal is also data related to the vibration state of the external machine equipment. First, the main controller module 2 sends a first control signal to the 1.8V power conversion module 3 to control the external battery voltage to be converted into 1.8V DC. The main controller module 2 also sends a second control signal to the 3.3V power conversion module 4 to control the external battery voltage to be converted into 3.3V DC. Through the conversion of the two power modules, a 1.8V DC power supply and a 3.3V DC power supply are provided in the industrial preventive maintenance data acquisition system. At the same time, the main controller module 2 can regulate other modules (such as analog-to-digital converter 5 and communication module 6) that require 1.8V DC power supply and 3.3V DC power supply by controlling the voltage conversion of the two power conversion modules. Secondly, the main controller module 2 is connected to the analog-to-digital converter 5 and the communication module 6 respectively, so that it can actively receive the relevant data information collected by the vibration sensor 7 transmitted by the analog-to-digital converter 5 and transmit these data related information to the external industrial gateway through the communication module 6. Preferably, the relevant data information collected by the vibration sensor 7 is mainly data related to the vibration state of the external machine equipment, which is mainly data related to the vibration frequency response signal of the machine equipment. The main controller module can also receive the query command transmitted by the external industrial gateway through the communication module 6, and collect the relevant data information of the vibration sensor 7 transmitted by the analog-to-digital converter 5 according to the query command to generate the response feedback signal of the query command. The response feedback signal is further transmitted to the external industrial gateway.

[0017] The power conversion module includes a 1.8V power conversion module 3 and a 3.3V power conversion module 4. The 1.8V power conversion module 3 is connected to the battery interface module 1, the main controller module 2 and the analog-to-digital converter 5 respectively, so as to provide 1.8V DC power to the analog-to-digital converter 5 as a working power source according to the first control signal of the main controller module 2. The 3.3V power conversion module 4 is connected to the battery interface module 1, the main controller module 2, the analog-to-digital converter 5 and the communication module 6 respectively, so as to provide 3.3V DC power to the analog-to-digital converter 5 and the communication module 6 as a working power source according to the second control signal of the main controller module 2.

[0018] The vibration sensor 7 mainly collects the vibration state related data (vibration frequency response signal related data) of the industrial machinery equipment outside the industrial preventive maintenance data acquisition system in real time, and then, the vibration sensor 7 converts the collected data related signal into an analog signal and transmits the analog signal to the analog-to-digital converter 5 to which it is connected.

[0019] The analog-to-digital converter 5 receives the analog signal transmitted from the vibration sensor 7. Then, the analog-to-digital converter 5 converts the analog signal into a digital signal. The analog-to-digital converter 5 transmits the digital signal to the main controller module 2 via the I2S interface. The analog-to-digital converter 2 is electrically connected to the 1.8V power conversion module 3 and the 3.3V power conversion module 4 respectively to obtain 1.8V and 3.3V working power supplies.

[0020] The communication module 6 is a channel for transmitting external industrial gateway query commands and external machine equipment vibration status related data between the industrial preventive maintenance data acquisition system of the present invention and the external industrial gateway. The communication module 6 is respectively connected to the main controller module 2 and the external industrial gateway to realize the transmission of external industrial gateway query commands and external machine equipment vibration status related data signals between the main controller module 2 and the external industrial gateway. The communication module 6 is electrically connected to the 3.3V power conversion module to obtain a 3.3V working power supply. Preferably, the communication module 6 adopts a Zigbee wireless communication module.

[0021] Figure 2 and Figure 3 The figure shows a specific embodiment of the front and back structures of a printed circuit board of an industrial predictive maintenance data acquisition system of the present invention. In this specific embodiment, the main controller module 2, the 1.8V power conversion module 3, the 3.3V power conversion module 4, the analog-to-digital converter 5 and the vibration sensor 7 are arranged on the front of the printed circuit board, and the battery interface module 1 and the communication module 6 are arranged on the back of the printed circuit board.

[0022] In a specific embodiment of the present invention, the vibration sensor 7 is arranged at the central position of the lower part of the printed circuit board. The main controller module 2 is arranged above the vibration sensor 7. The 3.3V power conversion module 4 is arranged at the upper right of the main controller module 2. The 1.8V power conversion module is arranged at the lower left side of the main controller module and is adjacent to the main controller module. The analog-to-digital converter 5 is arranged above the 1.8V power conversion module and is located on the left side of the main controller module.

[0023] In another specific embodiment of the present invention, a battery interface module 1 and a communication module 6 are arranged on the back of the printed circuit board. The battery interface module 1 is arranged at the center of the printed circuit board. The communication module 6 is arranged above the battery interface module 1 and adjacent to the battery interface module 1, and the communication module 6 is close to the edge of the printed circuit board.

[0024] When applied, the present invention can intelligently, quickly and continuously collect and process the operating status data of machine equipment, predict failures during machine operation, and give early warnings to machine operators, thereby controlling the maintenance cost of the machine and extending the service life of the machine.

[0025] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. An industrial preventive maintenance data acquisition system, wherein the industrial preventive maintenance data acquisition system is designed on a printed circuit board, characterized in that: include: A battery interface module, which is a channel for an external battery to access the industrial preventive maintenance data acquisition system; A main controller module, which maintains the stable operation of the industrial preventive maintenance data acquisition system, regulates the transmission of the internal current signal of the industrial preventive maintenance data acquisition system, receives an external industrial gateway query command, and transmits the received data related to the vibration status of the external machine equipment of the industrial preventive maintenance data acquisition system to the external industrial gateway on a regular basis or according to the query command, and the main controller module is electrically connected to the battery interface module to obtain a working power supply; A 1.8V power conversion module receives the first control signal of the main controller module and the current transmitted by the battery interface module, and then the 1.8V power conversion module converts the battery voltage into 1.8V direct current according to the first control signal; A 3.3V power conversion module receives the second control signal of the main controller module and the current transmitted by the battery interface module, and then the 3.3V power conversion module converts the battery voltage into 3.3V direct current according to the second control signal; A vibration sensor, which detects and collects data related to the vibration status of the external machinery and equipment of the industrial preventive maintenance data collection system in real time, and then the vibration sensor converts the data signal related to the vibration status of the external machinery and equipment of the industrial preventive maintenance data collection system into an analog signal; an analog-to-digital converter, which receives the analog signal and converts the analog signal into a digital signal, and then transmits the digital signal to the main controller module through an I2S interface, and the analog-to-digital converter is electrically connected to the 1.8V power conversion module and the 3.3V power conversion module respectively to obtain 1.8V and 3.3V working power supplies; and A communication module, which is a channel for transmitting the external industrial gateway query command and the vibration status related data of the external machine equipment of the industrial preventive maintenance data acquisition system between the industrial preventive maintenance data acquisition system and the external industrial gateway. The communication module is respectively connected to the main controller module and the external industrial gateway to realize the transmission of the external industrial gateway query command and the vibration status related data of the external machine equipment of the industrial preventive maintenance data acquisition system between the main controller module and the external industrial gateway. The communication module is electrically connected to the 3.3V power conversion module to obtain a 3.3V working power supply; The entire printed circuit board adopts a two-layer board structure, the front line of the printed circuit board is mainly horizontally routed, and the back line is mainly vertically routed, wherein the front of the printed circuit board is provided with: The vibration sensor is arranged at the central position of the lower part of the printed circuit board; The main controller module is arranged above the vibration sensor; The 3.3V power conversion module is arranged at the upper right of the main controller module; The 1.8V power conversion module is disposed on the left side of the lower part of the main controller module and is adjacent to the main controller module; and The analog-to-digital converter is arranged above the 1.8V power conversion module and located on the left side of the main controller module; The back side of the printed circuit board is provided with: The battery interface module is disposed at a central position of the printed circuit board; and The communication module is arranged above the battery interface module and is adjacent to the battery interface module, and the communication module is close to an edge of the printed circuit board; The data related to the vibration state of the external machinery and equipment of the industrial preventive maintenance data acquisition system is data related to the vibration frequency response signal of the external machinery and equipment of the industrial preventive maintenance data acquisition system.

2. The industrial preventive maintenance data acquisition system according to claim 1, characterized in that: The external battery is a 1.6Ah lithium battery with a nominal voltage of 3.6V.

3. The industrial preventive maintenance data acquisition system according to claim 1, characterized in that: The communication module is a ZigBee wireless communication module.

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