Electrical fault self-diagnosis system

Abstract

The present invention provides an electrical fault self-diagnosis system, including a sensor data acquisition module, a data depth processing module, a real-time data display module, an equipment status judgment module, an early warning information release module, and a human-machine interface, wherein the sensor data acquisition module collects switch quantity sensor signals of automation equipment; the data depth processing module detects the sudden rising edge or sudden falling edge of the switch quantity sensor signal and counts; the real-time data display module displays the count value of the switch quantity sensor signal on the human-machine interface; the equipment status judgment module compares the normal count value of the pre-stored switch quantity sensor signal with the actual count value of the counter within a cycle of the reciprocating operation of the automation equipment to judge the equipment status; the early warning information release module releases the information that the equipment status is abnormal on the human-machine interface. The system of the present invention can quickly locate faults and reduce fault downtime.

Description

Technical Field

[0001] The invention belongs to the technical field of artificial intelligence, and in particular relates to an electrical fault self-diagnosis system, which is suitable for self-analysis and self-diagnosis of electrical faults of reciprocating automation equipment. Background Art

[0002] Reciprocating automation equipment is equipped with a large number of external sensors, especially various switch sensors, such as liquid level switch sensors, temperature switch sensors, and pressure switch sensors. The switch sensors send contact signals as the automation equipment reciprocates, and have corresponding open and closed states. The electrical failures of reciprocating automation equipment are all caused by external sensor failures. External sensor failures can be divided into intermittent failures and permanent failures according to the type of failure manifestation. Intermittent failures are sometimes good and sometimes bad, and permanent failures cannot be restored to normal after failure. For permanent failures, the cause of the failure can be quickly found through the equipment's online monitoring program; for intermittent failures, such as external interference and internal degradation of the sensor, it is difficult to determine the fault point through the online monitoring program. At the same time, it is difficult to detect the sensor signal in time through spot inspection due to external interference and internal natural degradation.

[0003] At present, there is a lack of self-analysis and self-diagnosis systems for electrical faults in reciprocating automation equipment, and equipment faults cannot be quickly located, which prolongs the downtime and reduces the production efficiency of automation equipment. Summary of the invention

[0004] The purpose of the present invention is to provide an electrical fault self-diagnosis system for self-analysis and self-diagnosis of electrical faults of reciprocating automation equipment. The electrical fault self-diagnosis system includes a sensor data acquisition module, a data depth processing module, a real-time data display module, an equipment status judgment module, an early warning information release module, and a human-machine interface, wherein:

[0005] The sensor data acquisition module acquires the switch quantity sensor signal of the automation equipment, and sends the acquired switch quantity sensor signal to the data depth processing module;

[0006] The data depth processing module includes a programmable logic controller and a counter. The programmable logic controller processes the switch quantity sensor signal received from the sensor data acquisition module, detects one of the sudden rising edge or the sudden falling edge of the switch quantity sensor signal, and the counter counts one of the sudden rising edge or the sudden falling edge of the switch quantity sensor signal;

[0007] The real-time data display module collects the count value of the counter in real time, and displays the count value of the switch sensor signal on the human-machine interface;

[0008] The device state judgment module includes a memory, the memory pre-stores a normal count value of a switch quantity sensor signal within a reciprocating cycle of the automation device, and the device state judgment module compares the normal count value of the switch quantity sensor signal pre-stored in the memory with the actual count value of the counter within a reciprocating cycle of the automation device to judge the device state, and if the actual count value is consistent with the normal count value, the device state is judged to be "normal", and if the actual count value is inconsistent with the normal count value, the device state is judged to be "abnormal";

[0009] The early warning information publishing module publishes the information that the device status is "abnormal" as early warning information on the human-machine interface according to the device status judgment result of the device status judgment module.

[0010] Furthermore, in the above electrical fault self-diagnosis system, the counter accumulates a count each time the switch sensor signal has a sudden rising edge; or the counter accumulates a count each time the switch sensor signal has a sudden falling edge.

[0011] Furthermore, in the above-mentioned electrical fault self-diagnosis system, the sampling period of the sensor data acquisition module for acquiring the switch sensor signal of the automation equipment is one scanning period of the programmable logic controller.

[0012] The electrical fault self-diagnosis system of the present invention can perform real-time detection and fault warning on the working status of the switch quantity sensor of the reciprocating automation equipment, and the equipment abnormality information is released in real time through the human-machine interface, which is convenient for quickly locating the fault and reducing the fault downtime, thereby ensuring the further improvement of the production efficiency of the reciprocating automation equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the prior art descriptions. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. In the drawings:

[0014] Figure 1 It is a block diagram of the electrical fault self-diagnosis system of the present invention. DETAILED DESCRIPTION

[0015] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the specific embodiments of the present invention and the corresponding drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0016] Reference Figure 1 The electrical fault self-diagnosis system provided by the present invention is suitable for self-analysis and self-diagnosis of electrical faults of reciprocating automation equipment, including: a sensor data acquisition module 1, a data depth processing module 2, a real-time data display module 3, an equipment status judgment module 4, an early warning information release module 5, and a human-machine interface 6.

[0017] The sensor data acquisition module 1 acquires switch quantity sensor signals of the reciprocating automation equipment, and sends the acquired switch quantity sensor signals to the data depth processing module 2 .

[0018] The data depth processing module 2 includes a programmable logic controller and a counter. The programmable logic controller processes the switch quantity sensor signal received from the sensor data acquisition module 1, detects the sudden rising edge of the switch quantity sensor signal, and the counter counts the sudden rising edge of the switch quantity sensor signal. Each time the switch quantity sensor signal has a sudden rising edge, the counter accumulates the count. Of course, the programmable logic controller can also detect the sudden falling edge of the switch quantity sensor signal, and the counter counts the sudden falling edge of the switch quantity sensor signal. Each time the switch quantity sensor signal has a sudden falling edge, the counter accumulates the count.

[0019] The real-time data display module 3 collects the count value of the counter in real time, and displays the count value of the switch sensor signal on the human-machine interface 6.

[0020] The device status judgment module 4 includes a memory, and the memory pre-stores the normal count value of the switch quantity sensor signal of the reciprocating automated device in a reciprocating cycle. The device status judgment module 4 compares the normal count value of the switch quantity sensor signal pre-stored in its memory with the actual count value of the counter in the reciprocating cycle of the automated device to judge the device status. If the actual count value is consistent with the normal count value, the device status is judged to be "normal". If the actual count value is inconsistent with the normal count value, the device status is judged to be "abnormal". For example, the normal count value of the switch quantity sensor signal in the reciprocating cycle of the automated device is two times. If the actual count value of the counter in the reciprocating cycle of the device is also two times, the device status judgment module 4 judges the device status to be "normal". If the actual count value of the counter in the reciprocating cycle of the device exceeds or is less than two times, the device status judgment module 4 judges the device status to be "abnormal".

[0021] The warning information publishing module 5 publishes the information that the device status is “abnormal” as warning information on the human-machine interface 6 according to the device status judgment result of the device status judgment module 4 .

[0022] As a specific implementation, the sampling period of the sensor data acquisition module 1 to acquire the switch sensor signal of the reciprocating automation equipment is one scanning period of the programmable logic controller.

[0023] In summary, the electrical fault self-diagnosis system of the present invention has at least the following beneficial effects:

[0024] 1. It can detect the working status of the switch sensors of reciprocating automation equipment in real time and provide fault warning. The abnormal information of the equipment is released in real time through the human-machine interface, which is convenient for quickly locating the fault and reducing the downtime of the fault, thereby ensuring the further improvement of the production efficiency of the reciprocating automation equipment;

[0025] 2. Through the real-time data display module, equipment operation and maintenance personnel can perform preventive maintenance on the switch sensors of automation equipment based on real-time display data;

[0026] 3. No human intervention is required for analysis. The system automatically issues an abnormal warning of equipment status based on the judgment and analysis of the equipment status judgment module. At the same time, the fault information can be traced for easy query.

[0027] It should be noted that, in this article, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In addition, "front", "back", "left", "right", "upper" and "lower" in this article are all referenced to the placement state shown in the accompanying drawings.

[0028] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An electrical fault self-diagnosis system for self-analysis and self-diagnosis of electrical faults in reciprocating automation equipment, characterized in that: The electrical fault self-diagnosis system includes a sensor data acquisition module, a data depth processing module, a real-time data display module, an equipment status judgment module, an early warning information release module, and a human-machine interface, wherein: The sensor data acquisition module acquires the switch quantity sensor signal of the automation equipment, and sends the acquired switch quantity sensor signal to the data depth processing module; The data depth processing module includes a programmable logic controller and a counter, wherein the programmable logic controller processes the switch quantity sensor signal received from the sensor data acquisition module, detects one of the sudden rising edge or the sudden falling edge of the switch quantity sensor signal, and the counter counts one of the sudden rising edge or the sudden falling edge of the switch quantity sensor signal, wherein the counter accumulates one count each time the switch quantity sensor signal has a sudden rising edge; or the counter accumulates one count each time the switch quantity sensor signal has a sudden falling edge; The sampling period of the sensor data acquisition module for acquiring the switch sensor signal of the automation equipment is one scanning period of the programmable logic controller; The real-time data display module collects the count value of the counter in real time, and displays the count value of the switch sensor signal on the human-machine interface; The device state judgment module includes a memory, the memory pre-stores a normal count value of the switch quantity sensor signal within a reciprocating cycle of the automation device, and the device state judgment module compares the normal count value of the switch quantity sensor signal pre-stored in the memory with the actual count value of the counter within a reciprocating cycle of the automation device to judge the device state, if the actual count value is consistent with the normal count value, the device state is judged to be "normal", if the actual count value is inconsistent with the normal count value, the device state is judged to be "abnormal"; The early warning information publishing module publishes the information that the device status is "abnormal" as early warning information on the human-machine interface according to the device status judgment result of the device status judgment module.

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