A state monitoring and fault analysis system and method for a roll-over machine drive

Abstract

The application provides a state monitoring and fault analysis system and method for a dumper drive, the method comprising: a control device collecting first operation parameters of the dumper drive in real time, and transmitting the first operation parameters to an upper computer and a data server; the upper computer receiving and displaying the first operation parameters in real time, wherein the first operation parameters comprise driving operation parameters, braking parameters and coding parameters, the driving operation parameters comprise rotating speed, torque and current; the data server analyzes the first operation parameters to generate key detection parameters and returns the key detection parameters to the control device; the control device judges whether the dumper drive is in a normal operation state according to the key detection parameters, if yes, the real-time monitoring is continuously maintained; if no, fault alarm information is transmitted to the upper computer and displayed through the upper computer.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of fault analysis, in particular to a state monitoring and fault analysis system and method for a dumper drive. BACKGROUND

[0002] Coal is one of the main energy sources in China, and there are a large number of coal trains waiting to be unloaded at the port every day. The dumper system used for unloading coal at the port is the key equipment for production operation. The working environment of the dumper system is harsh, and once the driving equipment fails, on the one hand, it will greatly affect the production efficiency; on the other hand, equipment maintenance will occupy a lot of time and manpower; moreover, when the driving equipment fails seriously, it is easy to cause casualties.

[0003] At present, the commonly used driving monitoring method in the prior art is that the control system collects the operating parameters and fault codes of the frequency converter, and the fault reason is determined by professional technicians through fault troubleshooting or even fault reproduction after the equipment fails, and corresponding maintenance is performed. This monitoring method consumes a long time and has a low detection fault accuracy, so a system and method for realizing real-time state monitoring and fault analysis are needed to improve the efficiency and accuracy of determining the fault. SUMMARY

[0004] The embodiments of the present application provide a state monitoring and fault analysis system and method for a dumper drive, which can model the state in the dumper drive operation and monitor the driving operating state to make real-time judgments, so as to quickly give a judgment result and improve the efficiency of determining the fault.

[0005] To achieve the above-mentioned purpose, the present application adopts the following technical solutions:

[0006] In a first aspect, a state monitoring and fault analysis system for a dumper drive is provided, the dumper drive having a first driving end ring and a second driving end ring, the first driving end ring being driven by a main driving device, the main driving device including: a first brake, a first encoder, a main motor and a main frequency converter; the second driving end ring being driven by a slave driving device, the slave driving device including: a second brake, a second encoder, a slave motor and a slave frequency converter, the main driving device and the slave driving device being connected via a synchronization shaft, the system including:

[0007] a control device for collecting operating state parameters of the dumper drive, monitoring the driving state of the dumper drive in real time, and issuing operating control instructions to the dumper drive;

[0008] a host computer for displaying state monitoring information and fault alarm information of the dumper drive;

[0009] a data server for storing and processing the operating state parameters of the dumper drive and sending key detection parameters to the control system;

[0010] The main driving device, the host computer and the data server are in communication connection with the control device.

[0011] According to the system of the first aspect, since the system extracts the data storage and data analysis function from the control device, the load rate of the control device operation can be ensured; and through real-time operation analysis of the control device, the possible hidden troubles of the equipment can be judged in real time, the fault judgment and processing time is reduced, the efficiency of determining the fault is improved, and the unloading production efficiency is improved.

[0012] In a second aspect, a state monitoring and fault analysis method for a car dumper driving is provided, the method being applied to the state monitoring and fault analysis system for the car dumper driving of the first aspect, and the method comprising:

[0013] The control device collects the first operation parameters of the car dumper driving in real time, and transmits the first operation parameters to the host computer and the data server, the host computer receives and displays the first operation parameters in real time, wherein the first operation parameters include driving operation parameters, braking parameters and coding parameters, the driving operation parameters include rotation speed, torque and current;

[0014] The data server analyzes the first operation parameters to generate key detection parameters and returns the key detection parameters to the control device, the control device judges whether the car dumper driving is in a normal operation state according to the key detection parameters, if yes, the real-time monitoring is continued, and if no, the fault alarm information is transmitted to the host computer and displayed through the host computer.

[0015] According to the method of the second aspect, the control device collects the first operation parameters of the car dumper driving and sends operation control instructions; the host computer displays state monitoring and fault alarm information; the data server stores the first operation parameters, processes the data to generate key detection parameters and sends the key detection parameters to the control device, and the control device uses the key detection parameters to monitor and analyze the fault of the car dumper driving in operation, so that the operation state of the car dumper driving can be recorded and monitored in real time, the abnormal state of the driving can be recorded and tracked actively, the possible hidden troubles of the car dumper driving equipment can be judged and the processing time is reduced, and the unloading production efficiency is improved.

[0016] In combination with the second aspect, in a possible design scheme, the method further comprises:

[0017] The current operation phase of the car dumper driving is determined according to the current first operation parameters, wherein the operation phases of the car dumper driving include, in sequence, a start operation phase, a release operation phase, an acceleration operation phase, a constant-speed operation phase, a deceleration operation phase, a static operation phase and a stop operation phase.

[0018] With reference to the second aspect, in a possible design, the data server generates the key detection parameter by analyzing the first operation parameter, including:

[0019] The data server receives the first operation parameter uploaded by the control device in real time.

[0020] The data server performs drive monitoring parameter calculation based on the first operation parameter and a second operation parameter corresponding to a standard drive model in the data server, to obtain a key detection parameter, where the key detection parameter includes a drive operation analysis parameter and a drive synchronization analysis parameter.

[0021] With reference to the second aspect, in a possible design, the control device determines, in real time, whether the tipping drive is in a normal operation state according to the key detection parameter, including:

[0022] The control device determines a current operation phase of the tipping drive according to the current first operation parameter, and if the tipping drive is in a start operation phase, the control device determines, based on the current first operation parameter and the drive operation analysis parameter, whether the frequency converter is normally started and whether the motor excitation is normal in sequence, and if at least one of the determination results is no, corresponding fault alarm information is generated; if the determination results of both are yes, it is determined that the start operation phase of the tipping drive is in a normal operation state.

[0023] If the tipping drive is in a release operation phase, the control device determines, based on the current first operation parameter and the drive operation analysis parameter, whether the zero-speed torque is normally established and whether the brake is opened to the position in sequence, and if at least one of the determination results is no, corresponding fault alarm information is generated; if the determination results of both are yes, it is determined that the release operation phase of the tipping drive is in a normal operation state.

[0024] If the tipping drive is in an acceleration operation phase, the control device determines, based on the current first operation parameter and the drive operation analysis parameter, whether the ramp-up is normal and whether the output torque is normal in sequence, and if at least one of the determination results is no, corresponding fault alarm information is generated; if the determination results of both are yes, it is determined that the acceleration operation phase of the tipping drive is in a normal operation state.

[0025] If the tipping drive is in a constant-speed operation phase, the control device determines, based on the current first operation parameter and the drive operation analysis parameter, whether the speed curve is dithered and whether the output torque is normal in sequence, and if at least one of the determination results is no, corresponding fault alarm information is generated; if the determination results of both are yes, it is determined that the constant-speed operation phase of the tipping drive is in a normal operation state.

[0026] If the tipping machine drive is in the deceleration running stage, the control device judges in sequence whether to start deceleration and whether the ramp descending is normal based on the current first running parameter and the drive running analysis parameter, and generates corresponding fault alarm information if at least one of the two judgment results is no; if the judgment results of the two are yes, it is determined that the deceleration running stage of the tipping machine drive is in a normal running state;

[0027] If the tipping machine drive is in the static running stage, the control device judges in sequence whether the tipping machine zero speed is stable and whether the brake is closed normally based on the current first running parameter and the drive running analysis parameter, and generates corresponding fault alarm information if at least one of the two judgment results is no; if the judgment results of the two are yes, it is determined that the static running stage of the tipping machine drive is in a normal running state;

[0028] After determining that the static running stage of the tipping machine drive is in a normal running state, the tipping machine drive enters the stop running stage.

[0029] In combination with the second aspect, in a possible design scheme, the method further includes: when the control device judges whether the output torque is abnormal and whether the speed curve is jittering based on the current first running parameter and the drive running analysis parameter, if any of the two judgment results is yes, a fault stop command is generated accordingly, and the tipping machine drive stops running.

[0030] In combination with the second aspect, in a possible design scheme, the method further includes:

[0031] The control device monitors a rotation speed curve obtained based on the rotation speed in the drive running parameter to judge in real time a running parameter deviation of the main drive device and the driven device;

[0032] If the rotation speed in the rotation speed curve produces a deviation exceeding a first preset threshold value at a first preset angle, it is determined that the synchronization shaft is in a primary wear state;

[0033] If the rotation speed in the rotation speed curve continues to fluctuate within a first preset range, it is determined that the synchronization shaft is in an intermediate wear state;

[0034] If the rotation speed in the rotation speed curve continues to exceed the first preset range, it is determined that the synchronization shaft is in a separation state.

[0035] In combination with the second aspect, in a possible design scheme, the method further includes:

[0036] The control device monitors a torque curve obtained based on the torque in the drive running parameter to judge in real time a running parameter deviation of the main drive device and the driven device;

[0037] If the torque in the torque curve produces a deviation exceeding a second preset threshold value at a second preset angle, it is determined that the synchronization shaft is in a primary wear state;

[0038] If the torque in the torque curve continues to fluctuate within the second preset range, it is determined that the synchronous shaft is in a medium wear state;

[0039] If the torque corresponding to the main motor in the torque curve is full torque and the torque corresponding to the slave motor in the torque curve is zero torque, it is determined that the main driving device and the slave driving device are in a communication failure state.

[0040] In a third aspect, a state monitoring and fault analysis device based on a tipping machine drive is provided, and the device comprises:

[0041] A first processing module is configured to realize real-time collection of first running parameters of the tipping machine drive by the control device, and transmit the first running parameters to an upper computer and a data server, and the upper computer receives and displays the first running parameters in real time, wherein the first running parameters comprise driving running parameters, braking parameters and coding parameters, and the driving running parameters comprise rotation speed, torque and current.

[0042] A second processing module is configured to realize analysis of the first running parameters by the data server to generate key detection parameters returned to the control device, and the control device judges whether the tipping machine drive is in a normal running state in real time according to the key detection parameters, if yes, the real-time monitoring is continuously maintained, and if no, fault alarm information is transmitted to the upper computer and displayed through the upper computer.

[0043] In a fourth aspect, an electronic device is provided, comprising: one or more processors;

[0044] a memory;

[0045] one or more application programs, wherein the one or more application programs are stored in the memory and configured to be executed by the one or more processors, and the one or more programs are configured to execute the state monitoring and fault analysis method of the tipping machine drive in the second aspect and any possible design scheme combined with the second aspect.

[0046] In a fifth aspect, a computer readable storage medium is provided, and the computer readable storage medium stores program code, and the program code can be called and executed by a processor to execute the state monitoring and fault analysis method of the tipping machine drive in the second aspect and any possible design scheme combined with the second aspect.

[0047] In a sixth aspect, a computer program product is provided, comprising a computer program or instructions, when the computer program or instructions are executed on a computer, so that the computer executes the state monitoring and fault analysis method of the tipping machine drive in the second aspect and any possible design scheme combined with the second aspect.

[0048] Compared with the prior art, the beneficial effects of the present application are: on the one hand, since the system extracts the data storage and data analysis functions from the control device, the load rate of the control device operation can be ensured; and by performing real-time operation analysis through the control device, the possible hidden faults of the equipment can be judged in real time, the fault judgment and processing time is reduced, the efficiency of determining the fault is improved, and the unloading production efficiency is further improved. On the other hand, the control device collects the driving related operation parameters of the dumper, models the state in the dumper driving operation, and stores the related parameters in the data server. By establishing a standard driving model, the driving operation state of the dumper is judged in real time, the driving operation state of the dumper and the synchronization state of the driving are monitored, so that the driving operation state of the dumper can be recorded and monitored in real time, and the driving abnormal state can be recorded and tracked actively. The judgment of possible hidden faults of the dumper driving equipment and the processing time are reduced, and the unloading production efficiency is further improved. BRIEF DESCRIPTION OF DRAWINGS

[0049] Figure 1 The structural schematic diagram of the electronic device provided for the embodiments of the present application is shown in the figure.

[0050] Figure 2 The structural schematic diagram of the state monitoring and fault analysis system based on the dumper driving provided for the embodiments of the present application is shown in the figure.

[0051] Figure 3 The flowchart of the state monitoring and fault analysis method based on the dumper driving provided for the embodiments of the present application is shown in the figure. Figure 1

[0052] Figure 4 The flowchart of the state monitoring and fault analysis method based on the dumper driving provided for the embodiments of the present application is shown in the figure. Figure 2

[0053] Figure 5 The structural schematic diagram of the state monitoring and fault analysis device based on the dumper driving provided for the embodiments of the present application is shown in the figure. DETAILED DESCRIPTION

[0054] The technical solutions in the present application will be described below with reference to the accompanying drawings.

[0055] Please refer to Figure 1 , some possible embodiments of the present application provide an electronic device 10. The electronic device 10 can be a personal computer (PC), a tablet computer, a smart phone, a personal digital assistant (PDA), etc., or the electronic device 10 can be a network server, a database server, a cloud server, or a server integrated by multiple sub-servers, etc.

[0056] ​​Further, the electronic device 10 can include a memory 111, a communication interface 112, a communication bus 113, and a processor 114, wherein the processor 114, the communication interface 112, and the memory 111 are connected through the communication bus 113. The processor 114 is configured to execute executable modules, such as computer programs, stored in the memory 111. Figure 1 The components and structures of the electronic device 10 shown are only exemplary and are not limiting, and the electronic device 10 can also have other components and structures as needed.

[0057] The memory 111 can be a read-only memory (ROM) or other type of static storage device that can store static information and instructions, a random access memory (RAM) or other type of dynamic storage device that can store information and instructions, an electrically erasable programmable read-only memory (EEPROM), a compact disc read-only memory (CD-ROM) or other optical disk storage, an optical disk storage (including a compact disk, a laser disc, an optical disc, a digital versatile disc, a Blu-ray disc, etc.), a magnetic disk storage medium or other magnetic storage device, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and that can be accessed by a computer, but is not limited thereto. The memory 111 can be integrated with the processor 114 or can exist independently and be coupled to the processor 114 through the communication interface 112, and the embodiments of the present application do not make a specific limitation thereto.

[0058] It should also be understood that the memory in the embodiments of the present application can be a volatile memory or a non-volatile memory, or can include both volatile and non-volatile memories. Among them, the non-volatile memory can be a read-only memory (ROM), a programmable read-only memory (PROM), an erasable programmable read-only memory (EPROM), an electrically EPROM (EEPROM) or a flash memory. The volatile memory can be a random access memory (RAM) used as an external cache. By way of example, but not by way of limitation, many forms of random access memory (RAM) are available, such as static random access memory (SRAM), dynamic random access memory (DRAM), synchronous dynamic random access memory (SDRAM), double data rate synchronous dynamic random access memory (DDR SDRAM), enhanced SDRAM (ESDRAM), synchlink DRAM (SLDRAM) and direct rambus RAM (DR RAM).

[0059] The communication bus 113 can be an ISA bus (Industry Standard Architecture), a PCI bus (Peripheral Component Interconnect) or an EISA bus (Extended Industry Standard Architecture), etc. The communication bus can be divided into an address bus, a data bus, a control bus, etc. For convenience of representation, Figure 1 Only one bidirectional arrow is used in the middle, but it does not mean that there is only one bus or one type of bus.

[0060] The processor 114 can be an integrated circuit chip with processing capability. In implementation, the steps of the above method can be completed by integrated logic circuits or instructions in the form of software in the processor 114. The processor 114 described above can be a general-purpose processor, including a central processing unit (CPU), a network processor (NP), etc.; can also be a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, a discrete gate or transistor logic device, a discrete hardware component, and can implement or execute the disclosed methods, steps and logic block diagrams in the embodiments of the present application. The general-purpose processor can be a microprocessor or the processor can also be any conventional processor. The steps of the method disclosed in combination with the embodiments of the present application can be directly embodied as a hardware code processor for execution, or a combination of hardware and software modules in the code processor for execution. The software module can be located in a random access memory, a flash memory, a read-only memory, a programmable read-only memory or an electrically erasable programmable memory, a register, etc. mature storage media in the art.

[0061] The method performed by the device defined in the embodiments of the present application can be applied in the processor 114 or implemented by the processor 114. The processor 114 can cooperate with other modules or components in the electronic device 10 to perform the state monitoring and fault analysis method of the tipping machine drive. The execution of the state monitoring and fault analysis method of the tipping machine drive will be described in detail below.

[0062] The tipping machine is a large mechanical equipment used to unload the bulk material of railway open cars. The tipping machine can overturn or tilt the railway vehicle to unload the material, and is suitable for port, metallurgy, coal and thermal power industries with large transportation volume. The overturning of the tipping machine is realized by the tipping machine drive. Whether the tipping machine drive operates normally determines whether the tipping machine works normally. Therefore, it is necessary to monitor the operation state of the tipping machine drive.

[0063] Please refer to Figure 2In the embodiment of the present application, the roll-over machine drive has a first drive end ring and a second drive end ring, the first drive end ring is driven by a main drive device, and the main drive device comprises a first brake, a first encoder, a main motor and a main frequency converter; the second drive end ring is driven by a slave drive device, and the slave drive device comprises a second brake, a second encoder, a slave motor and a slave frequency converter, and the main drive device and the slave drive device are connected via a synchronous shaft.

[0064] Specifically, the roll-over machine has two drive end rings, which are a first drive end ring and a second drive end ring, so as to realize the overturning and returning actions of the roll-over machine; the first drive end ring is driven by a high-power variable-frequency main motor, and the second drive end ring is driven by a high-power variable-frequency slave motor; the high-power variable-frequency main motor and the high-power variable-frequency slave motor are connected through a synchronous shaft between a speed reducer, wherein the high-power variable-frequency main motor is driven by a main frequency converter, the high-power variable-frequency slave motor is driven by a slave frequency converter, torque master-slave synchronization is used between the main frequency converter and the slave frequency converter, the main frequency converter works in a speed loop, and the slave frequency converter works in a torque loop following the torque of the main motor.

[0065] In the embodiment of the present application, the first brake comprises a first high-speed brake and a first safety brake, the second brake comprises a second high-speed brake and a second safety brake, the first encoder comprises a first motor speed encoder and a first overturning angle encoder, the second encoder comprises a second motor speed encoder and a second overturning angle encoder, and each drive device further comprises a speed reducer, a synchronous shaft and a drive gear.

[0066] Based on the structure of the roll-over machine drive described above, the embodiment of the present application provides a state monitoring and fault analysis system based on the roll-over machine drive, which comprises: a control device for collecting running state parameters of the roll-over machine drive, monitoring the driving state of the roll-over machine drive in real time and issuing running control instructions to the roll-over machine drive; a host computer for displaying state monitoring information and fault alarm information of the roll-over machine drive; a data server for storing and processing the running state parameters of the roll-over machine drive and sending key detection parameters to the control system; and the main drive device, the host computer and the data server are respectively in communication connection with the control device.

[0067] As a possible implementation, the main frequency converter in the roll-over machine drive is in communication connection with the control device through a Profibus communication network, so as to realize the sending of the control instructions of the control device and the receiving of the corresponding state data of the roll-over machine drive; at the same time, the control device will also collect signals of the high-speed brake, the safety brake and the overturning angle encoder, and issue opening and closing instructions to the brake in combination with the state of the frequency converter.

[0068] It should be noted that the Profibus communication network used to realize the communication function in the embodiments of the present application is only an exemplary selection, and is not limited to this. For example, the communication connection between the main frequency converter and the control device can also be realized by using a wifi communication or a Bluetooth communication, and the specific communication connection mode is not limited herein.

[0069] As a possible implementation, the data server reads the operation state parameters collected by the control device through the OPC service, and synchronously stores the operation state parameters in the database in the data server, for historical data query and data processing. Moreover, the data server has a corresponding analysis on the operation state parameters to realize a state diagnosis function and a fault analysis function, and after the analysis and processing are completed, the processing result is generated as a key detection parameter and is sent to the control device.

[0070] It should be noted that the OPC service used to realize the communication function in the embodiments of the present application is only an exemplary selection, and is not limited to this. The specific communication mode is not limited herein.

[0071] After the control device receives the key detection parameter sent by the data server, the control device compares the real-time state operation parameter with the key detection parameter to determine whether a fault occurs. If the determination result is that a fault occurs, the control device pushes the alarm information to the upper computer operation interface to remind the production personnel in the production site, and the technical personnel can access and maintain the data service library through the network to obtain the fault information in real time. In the embodiments of the present application, the upper computer can be a SCADA (Supervisory Control And Data Acquisition, data acquisition and monitoring control system). The SCADA system has a man-machine interactive interface, so as to realize the interaction between the fault information and the production personnel.

[0072] It should be noted that the SCADA system used to realize the man-machine interaction in the embodiments of the present application is only an exemplary selection, and is not limited to this. For example, the computer, the smart phone, the tablet, the panel or the touch screen which can send the operation instruction, and the like can also be used, and the specific type of the upper computer is not limited herein.

[0073] Since the state monitoring and fault analysis system driven by the turnover machine extracts the data storage and data analysis function from the control device, the load rate of the control device can be ensured. Moreover, the control device can realize real-time operation analysis, and can determine the possible fault hidden danger of the equipment in real time, so as to reduce the fault determination and processing time, improve the efficiency of determining the fault, and further improve the unloading production efficiency.

[0074] Please refer to Figure 3, based on the above-described state monitoring and fault analysis system of the tipping machine drive, the embodiment of the present application provides a state monitoring and fault analysis method of the tipping machine drive, the method is applied to the state monitoring and fault analysis system of the tipping machine drive, and the method comprises the following steps.

[0075] Step S1: the control device collects first running parameters of the tipping machine drive in real time, and transmits the first running parameters to the upper computer and the data server; the upper computer receives and displays the first running parameters in real time, wherein the first running parameters comprise driving running parameters, braking parameters and coding parameters, the driving running parameters comprise rotating speed, torque and current;

[0076] Step S2: the data server analyzes the first running parameters to generate key detection parameters and returns the key detection parameters to the control device; the control device judges whether the tipping machine drive is in a normal running state according to the key detection parameters, if yes, the real-time monitoring is continuously maintained; if no, the fault alarm information is transmitted to the upper computer and displayed through the upper computer.

[0077] The specific execution process of the state monitoring and fault analysis method of the tipping machine drive will be described in detail below.

[0078] Step S1: the control device collects first running parameters of the tipping machine drive in real time, and transmits the first running parameters to the upper computer and the data server; the upper computer receives and displays the first running parameters in real time, wherein the first running parameters comprise driving running parameters, braking parameters and coding parameters, the driving running parameters comprise rotating speed, torque and current.

[0079] In the embodiment of the present application, the braking parameters comprise first high-speed braking parameters of a first high-speed brake, first safety braking parameters of a first safety brake, second high-speed braking parameters of a second high-speed brake and second safety braking parameters of a second safety brake; the coding parameters comprise first speed measuring coding parameters of a first motor speed measuring encoder, first angle coding parameters of a first turnover angle encoder, second speed measuring coding parameters of a second motor speed measuring encoder and second angle coding parameters of a second turnover angle encoder; and the driving running parameters comprise first rotating speed, first torque and first current corresponding to a high-power variable-frequency main motor and second rotating speed, second torque and second current corresponding to a high-power variable-frequency slave motor.

[0080] As a possible implementation, the control device collects the first operation parameter of the dumper drive in real time, and the normal operation process of the dumper drive can be specifically divided into different stages. The current corresponding operation stage of the dumper drive is determined according to the current first operation parameter, wherein the operation stages of the dumper drive include, in sequence, a start operation stage, a release operation stage, an acceleration operation stage, a constant-speed operation stage, a deceleration operation stage, a static operation stage and a stop operation stage.

[0081] Specifically, the start operation stage corresponds to the control device issuing a control instruction to excite the motor; the release operation stage corresponds to the motor excitation being completed, the zero-speed torque being established, and the brake being prepared to be released; the acceleration operation stage corresponds to the brake being opened to a position and the motor being accelerated to a preset speed by the frequency converter; the constant-speed operation stage corresponds to the dumper drive running at a speed; the deceleration operation stage corresponds to the motor being decelerated to zero by the frequency converter when the deceleration position is reached; the static operation stage corresponds to the dumper being static, the zero-speed torque being maintained, and the brake being started to be closed; and the stop operation stage corresponds to the brake being closed and the frequency converter being stopped. That is, according to different control instructions, different first operation state parameters are obtained, and different operation states of the dumper drive are obtained.

[0082] The control device collects the first operation state parameter in real time and uploads it to the data server and the upper computer. The data server performs corresponding data analysis and returns a control instruction; and the upper computer is used for real-time display of the first operation state parameter.

[0083] Step S2: The data server analyzes the first operation parameter to generate a key detection parameter and returns it to the control device. The control device judges whether the dumper drive is in a normal operation state in real time according to the key detection parameter. If yes, the real-time monitoring is continued; and if no, a fault alarm information is transmitted to the upper computer and displayed through the upper computer.

[0084] As a possible implementation, the data server analyzes the first operation parameter to generate a key detection parameter, which includes:

[0085] The data server receives the first operation parameter uploaded by the control device in real time;

[0086] The data server calculates a driving monitoring parameter based on the first operation parameter and a second operation parameter corresponding to a standard driving model in the data server, to obtain a key detection parameter, wherein the key detection parameter includes a driving operation analysis parameter and a driving synchronization analysis parameter.

[0087] In the embodiments of the present application, the first operating parameter and the second operating parameter are compared to determine whether the difference between them exceeds a preset threshold range, and a key detection parameter in different states is generated. If the difference between the two exceeds the preset threshold range, the generated key detection parameter indicates an abnormal operating state. If the difference between the two does not exceed the preset threshold range, the generated key detection parameter indicates a normal operating state.

[0088] The key detection parameter includes a drive operation analysis parameter and a drive synchronization analysis parameter. The drive operation analysis parameter is used to indicate the daily operation analysis state of the tipping machine drive. The drive synchronization analysis parameter is used to indicate the synchronization state of the high-power variable frequency master motor and the high-power variable frequency slave motor in the tipping machine drive. By analyzing the drive operation analysis parameter and the drive synchronization analysis parameter, it can be determined whether the tipping machine drive is normally operating and whether the master and slave motors of the tipping machine drive are synchronized.

[0089] As another possible implementation, the control device determines in real time whether the tipping machine drive is in a normal operating state according to the key detection parameter, including:

[0090] The control device determines the current operating phase of the tipping machine drive according to the current first operating parameter. If the tipping machine drive is in a start-up phase, the control device determines whether the frequency converter is normally started and whether the motor excitation is normal based on the current first operating parameter and the drive operation analysis parameter. If at least one of the two determination results is false, corresponding fault alarm information is generated. If the determination results of the two are both true, it is determined that the start-up phase of the tipping machine drive is in a normal operating state.

[0091] If the tipping machine drive is in a release operating phase, the control device determines whether the zero-speed torque is normally established and whether the brake is opened to the right position based on the current first operating parameter and the drive operation analysis parameter. If at least one of the two determination results is false, corresponding fault alarm information is generated. If the determination results of the two are both true, it is determined that the release operating phase of the tipping machine drive is in a normal operating state.

[0092] If the tipping machine drive is in an acceleration operating phase, the control device determines whether the ramp-up is normal and whether the output torque is normal based on the current first operating parameter and the drive operation analysis parameter. If at least one of the two determination results is false, corresponding fault alarm information is generated. If the determination results of the two are both true, it is determined that the acceleration operating phase of the tipping machine drive is in a normal operating state.

[0093] If the tipping machine drive is in the uniform speed running stage, the control device determines whether the speed curve is jittered and whether the output torque is normal based on the current first running parameter and the drive running analysis parameter in sequence, and if at least one of the two determination results is no, corresponding fault alarm information is generated; if the determination results of the two are yes, it is determined that the uniform speed running stage of the tipping machine drive is in a normal running state.

[0094] If the tipping machine drive is in the deceleration running stage, the control device determines whether the deceleration is started and whether the slope is normally descended based on the current first running parameter and the drive running analysis parameter in sequence, and if at least one of the two determination results is no, corresponding fault alarm information is generated; if the determination results of the two are yes, it is determined that the deceleration running stage of the tipping machine drive is in a normal running state.

[0095] If the tipping machine drive is in the static running stage, the control device determines whether the tipping machine zero speed is stable and whether the brake is normally closed based on the current first running parameter and the drive running analysis parameter in sequence, and if at least one of the two determination results is no, corresponding fault alarm information is generated; if the determination results of the two are yes, it is determined that the static running stage of the tipping machine drive is in a normal running state.

[0096] After it is determined that the static running stage of the tipping machine drive is in a normal running state, the tipping machine drive enters a stop running stage.

[0097] In the embodiment of the present application, since the running trend of the corresponding first running parameter is different when the tipping machine drive is in different running stages, the running stage of the tipping machine drive can be determined according to the change of the first running parameter in the historical data.

[0098] According to the different running states of the tipping machine, it is analyzed and determined whether the drive is abnormal, and for the serious fault directly leading to shutdown, fault shutdown is directly generated, and intuitive fault explanation is provided to the operators and technical personnel. For slight abnormal phenomenon, alarm record information is also generated for technical personnel to check.

[0099] As a possible implementation manner, the method further comprises: when the control device determines whether the output torque is abnormal and whether the speed curve is jittered based on the current first running parameter and the drive running analysis parameter, if any one of the two determination results is yes, a fault shutdown instruction is generated accordingly, and the tipping machine drive stops running.

[0100] In the embodiment of the present application, the running state of the output torque is determined by comparing the first running parameter with the preset second running parameter, and whether the speed curve is jittered is determined by whether the speed change value of the master-slave motor speed curve exceeds the preset speed change value within the preset time length.

[0101] At present, the turnover machine mostly adopts torque master-slave control, and a synchronous shaft is installed between the reducers of the driving motors of the two turnover machines. The master driving device receives the control instruction and speed setting sent by the control device, and adopts speed vector closed loop control. The slave driving device receives the control instruction sent by the control device and accepts the torque output setting of the master machine. For the synchronization information between the master driving device and the slave driving device, the synchronization state of the two can be monitored.

[0102] Please refer to Figure 4 Optionally, the control device monitors a speed curve obtained based on the speed in the driving operation parameter to judge the operation parameter deviation of the master driving device and the slave driving device in real time.

[0103] If the speed in the speed curve deviates from the first preset threshold at the first preset angle, it is determined that the synchronous shaft is in a primary wear state.

[0104] If the speed in the speed curve continues to fluctuate within the first preset range, it is determined that the synchronous shaft is in an intermediate wear state.

[0105] If the speed in the speed curve continues to exceed the first preset range, it is determined that the synchronous shaft is in a separation state.

[0106] In the embodiment of the application, the first preset angle is an angle value corresponding to a torque conversion point.

[0107] Optionally, the control device monitors a torque curve obtained based on the torque in the driving operation parameter to judge the operation parameter deviation of the master driving device and the slave driving device in real time.

[0108] If the torque in the torque curve deviates from the second preset threshold at the second preset angle, it is determined that the synchronous shaft is in a primary wear state.

[0109] If the torque in the torque curve continues to fluctuate within the second preset range, it is determined that the synchronous shaft is in an intermediate wear state.

[0110] If the torque corresponding to the master motor in the torque curve is full torque and the torque corresponding to the slave motor in the torque curve is zero torque, it is determined that the master driving device and the slave driving device are in a communication failure state.

[0111] In the embodiment of the application, the second preset angle is an angle value corresponding to a torque conversion point.

[0112] Please refer to Figure 5 The embodiment of the application also provides a state monitoring and fault analysis device 20 based on a turnover machine driving, and the device comprises:

[0113] The first processing module 210 is used for realizing that the control device collects the first operation parameter of the tipping machine drive in real time, and transmits the first operation parameter to the upper computer and the data server, the upper computer receives and displays the first operation parameter in real time, wherein the first operation parameter includes: drive operation parameter, brake parameter and coding parameter, the drive operation parameter includes: rotating speed, torque and current.

[0114] The second processing module 220 is used for realizing that the data server analyzes the first operation parameter to generate the key detection parameter returned to the control device, the control device judges whether the tipping machine drive is in the normal operation state in real time according to the key detection parameter, if yes, the real-time monitoring is continuously kept; if no, the fault alarm information is transmitted to the upper computer and displayed through the upper computer.

[0115] Since the system extracts the data storage and data analysis function from the control device, the load rate of the control device operation can be ensured; and the real-time operation analysis is carried out through the control device, the possible hidden troubles of the equipment are judged in real time, the fault judgment and processing time are reduced, the fault determination efficiency is improved, and then the unloading production efficiency is improved. On the other hand, the control device collects the related operation parameter of the tipping machine drive, models the state in the tipping machine drive operation, and stores the related parameter in the data server, the standard drive model is established, the running state of the tipping machine drive is judged in real time, the running state of the tipping machine drive and the synchronization state of the drive are monitored, so that the running state of the tipping machine drive can be recorded and monitored in real time, and the abnormal state of the drive is recorded and tracked actively, the possible hidden troubles of the tipping machine drive equipment are reduced, and the processing time is reduced, and then the unloading production efficiency is improved.

[0116] In summary, the application provides a state monitoring and fault analysis system and method of tipping machine drive, the method comprising: a control device collects the first operation parameter of the tipping machine drive in real time, and transmits the first operation parameter to the upper computer and the data server, the upper computer receives and displays the first operation parameter in real time, wherein the first operation parameter includes: drive operation parameter, brake parameter and coding parameter, the drive operation parameter includes: rotating speed, torque and current; the data server analyzes the first operation parameter to generate the key detection parameter returned to the control device, the control device judges whether the tipping machine drive is in the normal operation state in real time according to the key detection parameter, if yes, the real-time monitoring is continuously kept; if no, the fault alarm information is transmitted to the upper computer and displayed through the upper computer.

[0117] Various aspects, embodiments or features described herein can be presented in terms of systems that can include a number of devices, components, modules, and the like. It is to be understood and appreciated that the various systems can include additional devices, components, modules, etc. and / or can not include all of the devices, components, modules etc. discussed in connection with the figures. A combination of these approaches can also be used.

[0118] In addition, in embodiments of the present application, the words "example" and "exemplary" are used to mean serving as an example, instance, or illustration. Any implementation described herein as "example" or as an "exemplary implementation" should not be construed to be preferred or advantageous over other implementations. Rather, the use of the word example is intended to present concepts in a concrete manner. In addition, the term "and / or" as used herein refers to three possibilities: both of the items can be present, one of the items can be present, or neither of the items can be present.

[0119] The above-described embodiments can be implemented in part or in whole through software, hardware (e.g., circuitry), firmware, or any combination thereof. When implemented in software, the above-described embodiments can be implemented using one or more computer programs, and / or computer program elements, which are stored in a computer-readable medium. The computer-readable medium can be, for example, a memory, a computer diskette, an optical storage device, a RAM, a flash memory, a CD-ROM, a DVD, a silicon memory, and / or the like. The computer program elements / digital functions / commands can be downloaded to the computer from an external computer or external storage device via a computer network, a computer data input device, and / or the like. Furthermore, the computer program elements can also be downloaded to the computer across a computer network, a computer data input device, and / or the like.

[0120] It should be understood that the term "and / or" as used herein, is intended to represent a combination of the associated associated objects, or any of the associated objects alone. In addition, the term "or" as used herein, is intended to represent both the inclusive and exclusive "or" senses. That is, there can be three cases when "A or B" is used herein: A is true alone, B is true alone, or both A and B are true.

[0121] In this application, "at least one" means one or more, "multiple" means two or more. "At least one of the following (one)" or the like means any combination of these items, including any combination of single or multiple items. For example, at least one of a, b, or c can mean a, b, c, a-b, a-c, b-c, or a-b-c, where a, b, and c can be single or multiple.

[0122] It should be understood that the size of the sequence of the above processes in various embodiments of the present application does not mean the order of execution, the execution order of the processes should be determined by its function and inherent logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0123] Those of ordinary skill in the art can realize that the units and algorithm steps of the examples described in conjunction with the embodiments disclosed herein can be realized in electronic hardware or a combination of computer software and electronic hardware. Whether the functions are realized in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the present application.

[0124] Those skilled in the art can clearly understand that, for the convenience and brevity of the description, the specific working process of the above-described system, device and unit can refer to the corresponding process in the foregoing method embodiments, which will not be repeated here.

[0125] In several embodiments provided in the present application, it should be understood that the disclosed system, device and method can be implemented in other ways. For example, the above-described device embodiments are only schematic, for example, the division of the units is only a logical function division, and actual implementation can have another division manner, for example, a plurality of units or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the coupling or direct coupling or communication connection between the shown or discussed units can be indirect coupling or communication connection through some interface, device or unit, which can be electrical, mechanical or other form.

[0126] The units described as separate components can or can not be physically separated, and the components shown as units can or can not be physical units, that is, they can be located in one place, or they can be distributed on a plurality of network units. Part or all of the units can be selected according to actual needs to achieve the purpose of the embodiment.

[0127] In addition, each function unit in each embodiment of the present application can be integrated in one processing unit, or each unit can be physically present separately, or two or more units can be integrated in one unit.

[0128] The functions, if implemented in the form of software function units and sold or used as independent products, can be stored in a computer readable storage medium. Based on such understanding, the technical solutions of the present application, essentially or in part, or parts of the technical solutions can be embodied in the form of a software product. The computer software product is stored in a storage medium, and includes several instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present application. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM), random access memory (RAM), magnetic disk or optical disk, and various other media that can store program codes.

[0129] The above is merely specific embodiments of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present application, which shall be covered within the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.

Claims

1. A condition monitoring and fault analysis system for a tipper drive, wherein the tipper drive has a first drive end ring and a second drive end ring, the first drive end ring being driven by a main drive device, the main drive device comprising: First brake, first encoder, main motor and main frequency converter; The second drive end ring is driven by a slave drive device, which includes: a second brake, a second encoder, a slave motor, and a slave frequency converter. The main drive device and the slave drive device are connected via a synchronous shaft. The system comprises: A control device for collecting the operating status parameters of the tippler drive, monitoring the driving status of the tippler drive in real time, and issuing operating control commands to the tippler drive; A host computer used to display the status monitoring information and fault alarm information of the tipper drive; A data server for storing and processing the operating status parameters of the tipper drive and sending key detection parameters to the control device; The main drive device, the host computer, and the data server are respectively communicatively connected to the control device; The control device collects the first operating parameters of the tippler drive in real time and transmits the first operating parameters to the host computer and the data server. The host computer receives and displays the first operating parameters in real time. The first operating parameters include: drive operating parameters, braking parameters, and coding parameters. The drive operating parameters include: speed, torque, and current. The control device determines the current operating stage of the tippler drive based on the current first operating parameters. The operating stages of the tippler drive include, in sequence: start-up stage, release stage, acceleration stage, constant speed stage, deceleration stage, stationary stage, and stop stage. The data server analyzes the first operating parameters to generate key detection parameters and returns them to the control device. The control device uses the key detection parameters to determine in real time whether the tipper drive is in normal operating condition. If it is, it continues to monitor in real time; if not, it transmits fault alarm information to the host computer and displays it on the host computer. The control device monitors the speed curve obtained based on the speed in the drive operating parameters to determine the deviation of the operating parameters between the main drive device and the slave drive device in real time; if the speed in the speed curve deviates from the first preset threshold at a first preset angle, it is determined that the synchronous shaft is in the primary wear state; if the speed in the speed curve continues to fluctuate within a first preset range, it is determined that the synchronous shaft is in the intermediate wear state; if the speed in the speed curve continues to exceed the first preset range, it is determined that the synchronous shaft is in the separation state.

2. A method for condition monitoring and fault analysis of a tippler drive, wherein the method is applied to the condition monitoring and fault analysis system of the tippler drive as described in claim 1, characterized in that, The method includes: The control device collects the first operating parameters of the tipper drive in real time and transmits the first operating parameters to the host computer and data server. The host computer receives and displays the first operating parameters in real time. The first operating parameters include: drive operating parameters, braking parameters and coding parameters. The drive operating parameters include: speed, torque and current. The data server analyzes the first operating parameters to generate key detection parameters and returns them to the control device. The control device uses the key detection parameters to determine in real time whether the tipper drive is in normal operating condition. If it is, it continues to monitor in real time; if not, it transmits fault alarm information to the host computer and displays it on the host computer. The method further includes: The current operating stage of the tippler drive is determined based on the current first operating parameters. The operating stages of the tippler drive include, in sequence: start-up stage, release stage, acceleration stage, constant speed stage, deceleration stage, stationary stage, and stop stage. The control device monitors the speed curve obtained based on the speed in the drive operating parameters to determine the deviation of the operating parameters between the main drive device and the slave drive device in real time; if the speed in the speed curve deviates from the first preset threshold at a first preset angle, it is determined that the synchronous shaft is in the primary wear state; if the speed in the speed curve continues to fluctuate within a first preset range, it is determined that the synchronous shaft is in the intermediate wear state; if the speed in the speed curve continues to exceed the first preset range, it is determined that the synchronous shaft is in the separation state.

3. The method for monitoring the state and analyzing the faults of a tipper drive according to claim 2, characterized in that, The data server analyzes the first operating parameters to generate key detection parameters, including: The data server receives the first operating parameters uploaded by the control device in real time; The data server calculates the key detection parameters based on the first operating parameters and the second operating parameters corresponding to the standard driving model in the data server, and obtains the key detection parameters, wherein the key detection parameters include: driving operation analysis parameters and driving synchronization analysis parameters.

4. The method for condition monitoring and fault analysis of a tipper drive according to claim 3, characterized in that, The control device determines in real time whether the tipper drive is in normal operating condition based on the key detection parameters, including: The control device determines the current operating stage of the tippler drive based on the current first operating parameters. If the tippler drive is in the start-up stage, the control device sequentially judges whether the frequency converter has started normally and whether the motor excitation is normal based on the current first operating parameters and the drive operation analysis parameters. If at least one of the judgment results is negative, a corresponding fault alarm message is generated; if both judgment results are positive, it is determined that the start-up stage of the tippler drive is in normal operating condition. If the tipper drive is in the release operation phase, the control device sequentially determines whether the zero-speed torque is established normally and whether the brake is fully opened based on the current first operating parameter and the drive operation analysis parameter. If at least one of the determination results is negative, a corresponding fault alarm message is generated; if both determination results are positive, it is determined that the tipper drive is in normal operation during the release operation phase. If the tipper drive is in the acceleration phase, the control device sequentially judges whether the ramp ascent is normal and whether the output torque is normal based on the current first operating parameter and the drive operation analysis parameter. If at least one of the judgment results is negative, a corresponding fault alarm message is generated; if both judgment results are positive, it is determined that the acceleration phase of the tipper drive is in normal operation. If the tipper drive is in the constant speed operation phase, the control device sequentially judges whether the speed curve is jittering and whether the output torque is normal based on the current first operating parameter and the drive operation analysis parameter. If at least one of the judgment results is negative, a corresponding fault alarm message is generated; if both judgment results are positive, it is determined that the constant speed operation phase of the tipper drive is in normal operation. If the tippler drive is in the deceleration phase, the control device sequentially determines whether to start deceleration and whether the slope descent is normal based on the current first operating parameter and the drive operation analysis parameter. If at least one of the determinations is negative, a corresponding fault alarm message is generated; if both determinations are positive, it is determined that the deceleration phase of the tippler drive is in normal operation. If the tipper drive is in a stationary operation phase, the control device sequentially determines whether the tipper's zero speed is stable and whether the brake is properly closed based on the current first operating parameter and the drive operation analysis parameter. If at least one of the determinations is negative, a corresponding fault alarm message is generated; if both determinations are positive, it is determined that the tipper drive is in a normal operating state during the stationary operation phase. Once it is determined that the tippler drive is in normal operating condition during the stationary operation phase, the tippler drive enters the stop operation phase.

5. The method for condition monitoring and fault analysis of a tipper drive according to claim 4, characterized in that, The method further includes: when the control device determines whether the output torque is abnormal and whether the speed curve is jittering based on the current first operating parameters and the drive operation analysis parameters, if either of the determination results is yes, a corresponding fault stop command is generated, and the tipper drive stops running.

6. The method for monitoring the state and analyzing the faults of a tipper drive according to claim 2, characterized in that, The method further includes: The control device monitors the torque curve obtained based on the torque in the drive operating parameters to determine the deviation of the operating parameters between the main drive device and the slave drive device in real time. If the torque in the torque curve deviates from the second preset threshold at the second preset angle, it is determined that the synchronous shaft is in the initial wear state. If the torque in the torque curve continues to fluctuate within the second preset range, it is determined that the synchronous shaft is in a medium-level wear state. If the torque corresponding to the main motor in the torque curve is full torque and the torque corresponding to the slave motor in the torque curve is zero torque, it is determined that the main drive device and the slave drive device are in a communication failure state.

7. An electronic device, characterized in that, include: One or more processors; Memory; One or more applications, wherein the one or more applications are stored in the memory and configured to be executed by the one or more processors, the one or more applications being configured to perform the tipper drive condition monitoring and fault analysis method according to any one of claims 2-6.

8. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores program code that can be invoked by a processor to execute the method according to any one of claims 2-6.

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