A motor temperature and vibration online monitoring system for injection molding processing

Abstract

This invention discloses an online monitoring system for motor temperature and vibration in injection molding, comprising an Internet of Things (IoT) for information transmission; a magnetic temperature sensor probe for detecting motor temperature and a temperature controller connected to the magnetic temperature sensor probe; a vibration probe for detecting motor vibration; a serial port server connected to each temperature controller, and communication between the serial port server and the temperature controller is achieved via RS485 communication; and a factory switch connected to the serial port server, which is connected to the IoT. This structure avoids human error that may cause missed detections, ensuring real-time monitoring of the operation of each relevant motor. The system automatically detects abnormalities through online instruments and sensors and periodically pushes the detection results to the mobile devices of relevant personnel via the server. This allows for timely detection of early-stage anomalies, enabling prompt maintenance and repair, and preventing the motor from being completely damaged before the problem is discovered, thus improving equipment operating efficiency.

Description

Technical Field

[0001] This invention relates to the field of motor monitoring technology, and in particular to an online monitoring system for motor temperature and vibration in injection molding processes. Background Technology

[0002] Because the factory has many high-power motors, and most of them are located inside the machines, if we rely entirely on people to use thermal imaging cameras to regularly measure the temperature and conduct inspections, there will always be areas that cannot be covered. Therefore, sometimes some critical motors are missed in the inspection, and the actual operating status of the equipment cannot be understood in real time. This can lead to abnormal motor heating or even damage during machine operation, resulting in sudden shutdowns and subsequent repairs, which will seriously affect the efficiency of the equipment. Summary of the Invention

[0003] The purpose of this invention is to at least solve one of the technical problems existing in the prior art, and to provide an online monitoring system for motor temperature and vibration in injection molding, avoiding missed detections caused by human error, and ensuring real-time monitoring of the operation of each relevant motor. The system automatically detects through online instruments and sensors and pushes the detection results to the mobile devices of relevant personnel through a server on a regular basis. In this way, early abnormalities in the equipment can be detected in time, so that maintenance and upkeep can be carried out in a timely manner, avoiding the situation where the motor is completely damaged before it is discovered, which affects the operating efficiency of the equipment.

[0004] The present invention also provides an online monitoring system for motor temperature and vibration for injection molding, comprising:

[0005] The Internet of Things (IoT) is used for transmitting information;

[0006] A magnetic temperature sensor probe for detecting motor temperature and a temperature control instrument connected to the magnetic temperature sensor probe.

[0007] Vibration probe used to detect motor vibration;

[0008] A serial port server is connected to each temperature controller, and communication between the serial port server and the temperature controller is realized through RS485 communication.

[0009] A factory switch connected to a serial server; the factory switch is connected to the Internet of Things (IoT).

[0010] The factory switch is equipped with a judgment module to determine the severity of abnormal data, thereby ensuring the urgency and accuracy of the information sent.

[0011] Mobile devices used to receive information;

[0012] The online monitoring system includes the following installation steps:

[0013] S1. Layout: Draw a location diagram of relevant motors, serial servers, and switches on site to determine the final layout;

[0014] S2. Install instruments: Install temperature controllers, vibration probes and magnetic temperature sensor probes according to the layout determined in S1, and realize communication between the temperature controller and the field serial server through RS485 communication.

[0015] S3. Setting: Set the IP address of each serial port server, connect it to the factory switch via network cable to realize the connection between the server and the server. The server will push the collected data to the mobile devices of the equipment personnel through the Internet of Things platform to monitor the operation of the motor in real time.

[0016] S4. Normal transmission: Push real-time information to the mobile device at set intervals, including temperature and vibration index;

[0017] S5. Abnormal Transmission: When the switch receives abnormal data between multiple serial port servers, the judgment module determines the abnormal change value and prioritizes the transmission of data with larger abnormal change values. The judgment module also determines the harmfulness of the abnormal data change and prioritizes the transmission of data with greater harm. Finally, it determines the continuous acceleration value of the abnormal data and prioritizes the transmission of data with increasing continuous acceleration values.

[0018] According to the present invention, an online monitoring system for motor temperature and vibration in injection molding is provided. The mobile device includes smart devices such as mobile phones, tablets, computers, and electronic watches, and the vibration probe is connected to a vibration meter.

[0019] According to the present invention, an online monitoring system for motor temperature and vibration in injection molding is provided, wherein the magnetic temperature sensor probe and the vibration probe are located on the surface or inside the motor.

[0020] According to the present invention, an online monitoring system for motor temperature and vibration in injection molding is provided. The Internet of Things (IoT) is equipped with a timing module and an early warning module. The timing module transmits data such as the motor's operating status, temperature, and vibration over a certain period of time. When the motor's temperature and vibration are high, the early warning module bypasses the timing module and directly transmits the corresponding abnormal data to the mobile device.

[0021] According to the present invention, an online monitoring system for motor temperature and vibration in injection molding is provided. The Internet of Things further includes a setting module, which sets the temperature and vibration indices.

[0022] According to the present invention, an online monitoring system for motor temperature and vibration in injection molding is provided. The change value in S5 includes the increase in motor temperature and the increase in vibration frequency. The hazard is that the increase in motor vibration is more harmful than the increase in motor temperature. The continuous acceleration value is the ratio of the change in temperature heating rate to the time taken for this change or the ratio of the change in vibration frequency rate to the time taken for this change.

[0023] Beneficial effects

[0024] This invention can avoid missed detections caused by human error and ensure real-time monitoring of the operation of each relevant motor. The system automatically detects through online instruments and sensors and pushes the detection results to the mobile devices of relevant personnel through the server on a regular basis. In this way, early abnormalities can be detected in time, so that maintenance and upkeep can be carried out in a timely manner, avoiding the situation where the motor is completely damaged before it is discovered, which would affect the operating efficiency of the equipment.

[0025] This invention uses internal judgment to sort motors in real time according to their condition, thereby making reasonable arrangements for maintenance workers, avoiding serious damage to motor lifespan, and extending the service life of the motor. Attached Figure Description

[0026] The present invention will be further described below with reference to the accompanying drawings and embodiments;

[0027] Figure 1 This is a schematic diagram of the process of an online monitoring system for motor temperature and vibration in injection molding according to the present invention.

[0028] Figure 2 This is an internal flowchart of the Internet of Things (IoT) of an online monitoring system for motor temperature and vibration in injection molding, according to the present invention.

[0029] Figure 3 This is a logic diagram of abnormal data transmission for an online monitoring system for motor temperature and vibration in injection molding, according to the present invention. Detailed Implementation

[0030] This section will describe in detail specific embodiments of the present invention. Preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and overall technical solution of the present invention, but they should not be construed as limiting the scope of protection of the present invention.

[0031] Reference Figure 1-3 An embodiment of the present invention provides an online monitoring system for motor temperature and vibration in injection molding, comprising:

[0032] The Internet of Things (IoT) is used to transmit information. The IoT has a timing module and an early warning module. The timing module transmits data such as the motor's operating status, temperature, and vibration at regular intervals. When the motor's temperature and vibration are high, the early warning module bypasses the timing module and directly transmits the corresponding abnormal data to the mobile device. The IoT also includes a setting module, which sets the temperature and vibration indices.

[0033] A magnetic temperature sensor probe for detecting motor temperature and a temperature control instrument connected to the magnetic temperature sensor probe, the magnetic temperature sensor probe being located on the surface or inside the motor.

[0034] A vibration probe used to detect motor vibration; the vibration probe is connected to a vibration meter and is located on the surface of the motor.

[0035] A serial port server is connected to each temperature controller, and communication between the serial port server and the temperature controller is realized through RS485 communication.

[0036] A factory switch connected to a serial server; the factory switch is connected to the Internet of Things (IoT).

[0037] The factory switch is equipped with a judgment module to determine the severity of abnormal data, thereby ensuring the urgency and accuracy of the information sent.

[0038] Mobile devices used to receive information include smart devices such as mobile phones, tablets, computers, and smartwatches;

[0039] The online monitoring system includes the following installation steps:

[0040] S1. Layout: Draw a location diagram of relevant motors, serial servers, and switches on site to determine the final layout;

[0041] S2. Install instruments: Install temperature controllers, vibration probes and magnetic temperature sensor probes according to the layout determined in S1, and realize communication between the temperature controller and the field serial server through RS485 communication.

[0042] S3. Setting: Set the IP address of each serial port server, connect it to the factory switch via network cable to realize the connection between the server and the server. The server will push the collected data to the mobile devices of the equipment personnel through the Internet of Things platform to monitor the operation of the motor in real time.

[0043] The push process is as follows: 1. Through the timing module set within the Internet of Things, the corresponding information is input into the mobile device at certain intervals;

[0044] 2. Through the early warning module inside the Internet of Things, when the internal temperature or vibration exceeds the value set by the setting module, the corresponding abnormal data is directly transmitted to the mobile device.

[0045] S4. Normal transmission: Push real-time information to the mobile device at set intervals, including temperature and vibration index;

[0046] S5. Abnormal Transmission: When the switch receives abnormal data between multiple serial port servers, the judgment module determines the severity of the abnormal data changes and prioritizes the transmission of data with greater severity. Then, the judgment module determines the abnormal change value and prioritizes the transmission of data with larger abnormal change values. It also determines the continuous acceleration value of the abnormal data and prioritizes the transmission of data with increasing continuous acceleration values.

[0047] The changes include the increase in motor temperature and the increase in vibration frequency. The hazard is that the increase in motor vibration is more harmful than the increase in motor temperature. When the temperature exceeds a predetermined value, the temperature hazard is relatively high. The continuous acceleration value is the ratio of the change in temperature heating rate to the time taken for this change or the ratio of the change in vibration frequency rate to the time taken for this change.

[0048] After the hazard assessment, data with significant hazard, such as vibration or temperature exceeding preset values, are entered into the change value assessment. Based on the change value determination, the data with the largest increase or exceeding the set value is transmitted downwards. Finally, based on the continuous change value, the fastest increasing data is transmitted to the Internet of Things for notification.

[0049] Change value = Increase in temperature or vibration frequency / Increase time; Continuous change value = Change / Increase time.

[0050] Simultaneously, based on the above methods, the start and stop of the motor can be remotely controlled to prevent direct damage to the motor. During the shutdown process, the temperature drop of the motor can be obtained based on the correspondence between the intermittent time and the temperature drop, where the correspondence between the intermittent time and the temperature drop is the relationship between the intermittent time and the temperature drop, and the corresponding data can be stored.

[0051] Obtaining the preset data:

[0052] By running the motor normally, we obtain its operating temperature, initial temperature increase, vibration frequency, and maximum operating temperature. We also obtain corresponding normal temperature, temperature increase, and vibration data. We remove unreasonable data (delete data that is significantly different from other data) to obtain the range of set values, thereby limiting the data.

[0053] Conditions for the motor to stop running:

[0054] 1. Under maintenance: The motor is manually stopped by maintenance personnel.

[0055] 2. Temperature Exceedance Warning: When the temperature rises to a level that is likely to damage the motor (based on data obtained from detection), the internal system will stop the motor from running.

[0056] 3. Vibration Exceeds Warning: When the vibration frequency or vibration exceeds the limit (data obtained through experiments showing that the motor cannot work normally), the internal system will stop the motor's operation.

[0057] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. An online monitoring system for motor temperature and vibration in injection molding, characterized in that, include: The Internet of Things (IoT) is used for transmitting information; A magnetic temperature sensor probe for detecting motor temperature and a temperature control instrument connected to the magnetic temperature sensor probe. Vibration probe used to detect motor vibration; A serial port server is connected to each temperature controller, and communication between the serial port server and the temperature controller is realized through RS485 communication. A factory switch connected to a serial server; the factory switch is connected to the Internet of Things (IoT). The Internet of Things (IoT) is equipped with a timing module and an early warning module. The timing module transmits the motor's operating status, temperature, and vibration data at regular intervals. When the motor's temperature and vibration are high, the early warning module bypasses the timing module and directly transmits the corresponding abnormal data to the mobile device. The factory switch is equipped with a judgment module to determine the severity of abnormal data, thereby ensuring the urgency and accuracy of the information sent. Mobile devices used to receive information; The online monitoring system includes the following installation steps: S1. Layout: Draw a location diagram of relevant motors, serial servers, and switches on site to determine the final layout; S2. Install instruments: Install temperature controllers, vibration probes and magnetic temperature sensor probes according to the layout determined in S1, and realize communication between the temperature controller and the field serial server through RS485 communication. S3. Setting: Set the IP address of each serial port server, connect it to the factory switch via network cable to realize the connection between the server and the server. The server will push the collected data to the mobile devices of the equipment personnel through the Internet of Things platform to monitor the operation of the motor in real time. S4. Normal transmission: Push real-time information to the mobile device at set intervals, including temperature and vibration index; S5. Abnormal Transmission: When the switch receives abnormal data between multiple serial port servers, the judgment module determines the severity of the abnormal data changes and prioritizes the transmission of data with greater severity. The judgment module also determines the abnormal change value and prioritizes the transmission of data with larger abnormal change values. Furthermore, it determines the continuous acceleration value of the abnormal data and prioritizes the transmission of data with increasing continuous acceleration values. The change value in S5 includes the increase in motor temperature and the increase in vibration frequency. The hazard is that the increase in motor vibration is more harmful than the increase in motor temperature. The continuous acceleration value is the ratio of the change in temperature heating rate to the time taken for this change or the ratio of the change in vibration frequency rate to the time taken for this change.

2. The online monitoring system for motor temperature and vibration in injection molding as described in claim 1, characterized in that, The mobile device includes a mobile phone, tablet, computer, or electronic watch, and the vibration probe is connected to a vibration meter.

3. The online monitoring system for motor temperature and vibration in injection molding as described in claim 1, characterized in that, The magnetic temperature sensor probe and the vibration probe are located on the surface or inside the motor.

4. The online monitoring system for motor temperature and vibration in injection molding as described in claim 1, characterized in that, The Internet of Things also includes a setting module, which sets the temperature and vibration index.

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