A motor fault monitoring system for industrial Internet of Things

Abstract

The invention discloses a motor fault monitoring system for an industrial Internet of Things, and relates to the technical field of motor fault monitoring. The invention collects operating data of all motors in industrial equipment, and analyzes whether each motor has a fault. When a fault occurs, it is analyzed whether a backup motor needs to be configured for the faulty motor according to the situation of the position where the faulty motor is configured. If configuration is required, a suitable backup motor is selected, and the maintenance type is analyzed according to the operating data of each faulty motor, and a motor maintenance list is generated. When the maintenance personnel perform maintenance, the maintenance personnel are monitored, so as to improve the accuracy of the motor fault monitoring and analysis results and the timeliness of fault discovery, reduce the difficulty and cost of maintenance, and select a backup motor for the position where the backup motor needs to be configured, so as to reduce the cost of the backup motor and improve the stability and safety of the backup motor performance, and reduce the duration of equipment downtime.

Description

Technical Field

[0001] The present invention relates to the technical field of motor fault monitoring, and in particular to a motor fault monitoring system of an industrial Internet of Things. Background Art

[0002] Industrial Internet of Things is a way to apply Internet of Things technology to industrial environments. By combining industrial equipment, sensors, control systems and data analysis, it promotes the intelligence and automation of industrial processes. As the core power source of industrial equipment, the operating status of the motor directly affects the efficiency and capacity of the entire production line. Through intelligent fault monitoring of the motor, motor faults can be discovered and handled in a timely manner, thereby improving production efficiency and reducing labor costs.

[0003] Traditional maintenance methods often involve regular inspections or comparing the collected motor operating data with historical data to determine whether the motor has a fault. However, traditional maintenance methods have at least the following shortcomings: 1. Regular inspections may not detect potential faults in a timely manner, causing the fault to expand, increasing the difficulty and cost of maintenance. For industrial equipment with multiple motors, different motors drive different components and are in different environments. Therefore, the models and sizes of motors selected for each replacement at different locations may not be the same, resulting in the operating data during operation may not be the same. Therefore, only comparing with historical data cannot improve the accuracy of fault monitoring results.

[0004] 2. For industrial equipment with multiple motors, if some motors are responsible for performing key tasks, such as the core drive of a production line, or motors with a high failure rate due to installation location or environmental conditions need spare parts so that they can be quickly replaced in the event of a failure, reducing the length of equipment downtime and thus reducing production losses. However, in traditional technologies, the historical data of historical motors in motor configuration positions and the functions of motors are not analyzed, and the situation of each motor configuration position cannot be understood, nor can backup motors be configured for key positions. When a motor fails, it cannot be quickly replaced to reduce the length of equipment downtime, thereby increasing production losses. On the other hand, when selecting a backup motor, the specifications of the backup motor should be similar to the scale of the motor to ensure that no large-scale changes or adjustments are required when replacing the backup motor. At the same time, cost and performance need to be considered to reduce the cost and risk of motor operation. However, traditional technologies lack analysis of motor specifications, cost and performance, and then select backup motors, which cannot reduce the cost and safety of backup motor operation. At the same time, when replacing the backup motor, the smoothness of the backup motor operation cannot be guaranteed, thus affecting the production efficiency of industrial equipment. Summary of the invention

[0005] In view of the above-mentioned technical deficiencies, an object of the present invention is to provide a motor fault monitoring system for industrial Internet of Things.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solution: The present invention provides a motor fault monitoring system for industrial Internet of Things, including: a motor monitoring module, a server and an execution monitoring module.

[0007] The motor monitoring module is used to collect the operating data and environmental data of each motor in the industrial equipment and send it to the server.

[0008] The server is used to receive the operating data of each motor and analyze whether each motor is faulty. If at least one motor is faulty, each faulty motor is recorded as a faulty motor, and the functional data and historical monitoring records of the equipment motor are obtained. According to the environmental data of each faulty motor, it is analyzed whether each faulty motor needs to be configured with a backup motor, and each faulty motor that needs to be configured with a backup motor is recorded as a marked motor. At the same time, the backup motor corresponding to each marked motor is selected, and then a motor maintenance order is generated and sent to the maintenance personnel.

[0009] The execution monitoring module is used to collect the maintenance data of the maintenance personnel when they perform motor maintenance, monitor the maintenance status of the maintenance personnel, and perform corresponding monitoring operations.

[0010] The beneficial effects of the present invention are as follows: the present invention provides a motor fault monitoring system for an industrial Internet of Things, which collects the operating data of all motors in industrial equipment and analyzes whether each motor has a fault. When a fault occurs, it analyzes whether the faulty motor needs to be configured with a backup motor based on the location where the faulty motor is configured. If configuration is required, a suitable backup motor is selected, and the maintenance type is analyzed based on the operating data of each faulty motor, and a motor maintenance order is generated. When the maintenance personnel are performing maintenance, the maintenance personnel are monitored, which solves the shortcomings of motor fault monitoring in traditional technologies, improves the accuracy of motor fault monitoring and analysis results and the timeliness of fault discovery, reduces maintenance difficulty and cost, and selects backup motors for locations where backup motors need to be configured. While reducing the cost of backup motors, the stability and safety of backup motor performance are improved, and the motor is quickly replaced when it fails, reducing the length of equipment downtime, thereby reducing production losses. In addition, the behavior of maintenance personnel is monitored to ensure the transparency of the maintenance process and the quality and effect of motor maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. 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 paying creative work.

[0012] Figure 1It is a schematic diagram of the system structure connection of the present invention. DETAILED DESCRIPTION

[0013] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. 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 creative work are within the scope of protection of the present invention.

[0014] See also Figure 1 As shown, a motor fault monitoring system of the industrial Internet of Things includes: a motor monitoring module, a server and an execution monitoring module.

[0015] The motor monitoring module is used to collect the operating data and environmental data of each motor in the industrial equipment and send it to the server.

[0016] It should be noted that various sensors are deployed in each motor of industrial equipment to collect the operation data and environmental data of each motor, wherein the operation data includes vibration frequency and noise volume, etc.; the environmental data includes ambient temperature and dust concentration, etc. The various sensors include but are not limited to vibration sensors, noise sensors, temperature sensors and dust concentration sensors.

[0017] Industrial equipment includes but is not limited to industrial fans, machine tools and loaders. Industrial fans use multiple motors to drive different fans or impellers to achieve air circulation, ventilation or exhaust; machine tools are equipped with multiple motors for different axial movements, feed actions and spindle drives; loaders are equipped with multiple motors inside to drive different hydraulic systems, motion devices and working devices.

[0018] The server is used to receive the operating data of each motor and analyze whether each motor is faulty. If at least one motor is faulty, each faulty motor is recorded as a faulty motor, and the functional data and historical monitoring records of the equipment motor are obtained. According to the environmental data of each faulty motor, it is analyzed whether each faulty motor needs to be configured with a backup motor.

[0019] In the above, the functional data and historical monitoring records of the equipment motor are stored in the motor fault monitoring system. The functional data includes the control tasks corresponding to the motors in each configuration position, where the control tasks are the driving parts. For example, the machine tool is equipped with multiple motors for different axial movements, feed actions and spindle drives. Therefore, the control tasks of each motor in the machine tool include axial movement, feed actions and spindle drives. The historical monitoring records include but are not limited to the configuration position of each faulty motor, the historical environmental data corresponding to each configuration position, the number of failures of each historical motor in each configuration position, the maintenance time of each historical motor in each configuration position, and the actual life of each historical motor in each configuration position.

[0020] In a specific embodiment, the specific process of analyzing whether each motor is faulty is as follows: obtaining the safe operation data interval of each motor from the equipment control center, comparing the operating data of each motor with its corresponding safe operation data interval, if the operating data of a motor is not within its corresponding safe operation data interval, it indicates that the motor is faulty, otherwise it indicates that the motor is not faulty, in this way, analyzing whether each motor is faulty.

[0021] In another specific embodiment, the analysis of whether each faulty motor needs to be configured with a backup motor is performed as follows: obtaining the configuration position of each faulty motor, the historical environmental data corresponding to each configuration position, the number of failures of each historical motor in each configuration position, the maintenance duration of each historical motor in each configuration position, and the actual life of each historical motor in each configuration position from the historical monitoring records of the equipment motor; obtaining the control task corresponding to the motor at each configuration position from the functional data of the equipment motor.

[0022] The control tasks corresponding to the motors at each configuration position are compared with the key control task set set by the equipment control center. If the control task corresponding to the motor at a certain configuration position is the same as a key control task in the key control task set, it indicates that the category of the motor at this configuration position is a Class I motor; otherwise, it indicates that the motor at this configuration position is marked as a Class II motor, so as to obtain the category of the motors at each configuration position.

[0023] According to the environmental data corresponding to each faulty motor, the historical environmental data corresponding to each configuration position and the configuration position of each faulty motor, the environmental state coefficient of each configuration position is analyzed; the environmental state coefficient includes the values ​​of 1 and -1. When the environmental state coefficient of a configuration position is 1, it indicates that the environment of the configuration position is normal. When the environmental state coefficient of a configuration position is -1, it indicates that the environment of the configuration position is abnormal.

[0024] In the above, the environmental status coefficient of each configuration position is analyzed, and the specific process is as follows: the reference environmental operation data interval of the industrial equipment operation is obtained from the equipment control center, and the environmental data of each configuration position is obtained based on the environmental data and configuration position corresponding to each faulty motor, and the average value is calculated with the historical environmental data corresponding to each configuration position to obtain the average environmental data of each configuration position.

[0025] Analyze the model expression according to the environmental state: , get the environmental state coefficient of the i-th configuration position , where represents the average environmental data of the i-th configuration position, It represents the reference environment operation data interval of the industrial equipment operation, i represents the number of each configuration position, and i is a positive integer.

[0026] The loss coefficient of the motor in each configuration position is analyzed based on the number of historical failures of each motor in each configuration position, the maintenance duration of each historical motor in each configuration position, and the actual life of each historical motor in each configuration position. The loss coefficient contains values ​​of 1 and -1. When the loss coefficient of the motor in a certain configuration position is -1, it indicates that the motor in this configuration position is easy to be damaged. When the loss coefficient of the motor in a certain configuration position is 1, it indicates that the motor in this configuration position is not easy to be damaged.

[0027] In the above, the loss coefficient of the motor in each configuration position is analyzed, and the specific process is as follows: the reference life and limit fault number of each historical motor in each configuration position are obtained from the motor record of the motor fault monitoring system, and are recorded as and , i represents the number of each configuration position, g represents the number of each historical motor, and both i and g are positive integers.

[0028] The maintenance duration of each historical motor in each configuration position is accumulated to obtain the total maintenance duration of each historical motor in each configuration position, which is recorded as .

[0029] The expression of the loss coefficient analysis model is: , get the loss coefficient of the motor in the i-th configuration position , where f represents the total number of historical motors, , They represent the actual life and failure times of the g-th historical motor in the i-th configuration position, respectively. T represents the average life of the historical motor. , are the proportional coefficient of the preset life and the proportional coefficient of the number of failures, respectively. is the preset reference loss assessment coefficient.

[0030] The average life of the historical motor is calculated by averaging the total maintenance time of each historical motor in each configuration position.

[0031] Furthermore, the proportional coefficient of life and the proportional coefficient of failure number are set as follows: the actual life of each historical motor in each configuration position is calculated by difference, the maximum difference is selected as the life difference of each configuration position, and the minimum actual life is selected as the minimum life of each configuration position, the life difference of each configuration position is divided by the minimum life to obtain the life fluctuation value of each configuration position, and then the mean is calculated to obtain the average life fluctuation value of the motor.

[0032] The difference of the number of failures of each historical motor in each configuration position is calculated, the maximum difference is selected as the difference of the number of failures of each configuration position, and the maximum number of failures is selected as the maximum number of failures of each configuration position. The difference of the number of failures of each configuration position is divided by the maximum number of failures to obtain the fluctuation value of the number of failures of each configuration position, and then the mean is calculated to obtain the fluctuation value of the average number of failures of the motor.

[0033] The motor average life fluctuation value is divided by the sum of the motor average life fluctuation value and the motor average number of failure fluctuation values ​​to obtain the life proportionality coefficient. The motor average number of failure fluctuation value is divided by the sum of the motor average life fluctuation value and the motor average number of failure fluctuation values ​​to obtain the failure proportionality coefficient.

[0034] It should be noted that the reference loss evaluation coefficient is used to judge whether the configuration position has a critical value for the motor loss, and the value is set by the engineer of the industrial equipment. The calculation result is the loss evaluation coefficient of the motor in the i-th configuration position; for example, when the loss evaluation coefficient of the motor in the i-th configuration position is 18, the reference loss evaluation coefficient is 23, 18<23, indicating that the i-th configuration position does not cause much loss to the motor.

[0035] According to the type of motor at each configuration position, the environmental state coefficient of each configuration position, the loss coefficient of the motor in each configuration position and the configuration position of each faulty motor, determine whether each faulty motor needs to be configured with a backup motor.

[0036] In the above, the specific process of confirming whether each faulty motor needs to be configured with a backup motor is as follows: according to the configuration position of each faulty motor, the category of each faulty motor is obtained; if the category of a faulty motor is a Class I motor, and at least one of the environmental state coefficient and loss coefficient of the configuration position corresponding to the faulty motor is -1, it indicates that the faulty motor needs to be configured with a backup motor; if the environmental state coefficient and loss coefficient of the configuration position corresponding to the faulty motor are both 1, it indicates that the faulty motor does not need to be configured with a backup motor.

[0037] If the category of a faulty motor is a Class II motor, and the environmental state coefficient and loss coefficient of the corresponding configuration position of the faulty motor are both -1, it indicates that the faulty motor needs to be configured with a backup motor; if at least one of the environmental state coefficient and loss coefficient of the corresponding configuration position of the faulty motor is 1, it indicates that the faulty motor does not need to be configured with a backup motor, so as to confirm whether each faulty motor needs to be configured with a backup motor.

[0038] The server is also used to record each faulty motor that needs to be configured with a backup motor as a marked motor, select a backup motor corresponding to each marked motor, and then generate a motor maintenance order and send it to the maintenance personnel.

[0039] In a specific embodiment, the selection of backup motors corresponding to each marked motor is as follows: the specifications of each marked motor are obtained, and the usage parameters and prices corresponding to each motor in the motor fault monitoring system are extracted, and the specifications, safe operating environment data range, reference life and maximum number of failures are obtained from the usage parameters of each motor.

[0040] Compare each motor with each historical motor in each configuration position. If a motor is the same as a historical motor in a configuration position, the actual life, number of failures and total maintenance time of the historical motor are used as the actual life, number of failures and total maintenance time of the motor, so as to obtain the actual life, number of failures and total maintenance time of each motor, and perform mean calculation to obtain the average actual life, average number of failures and average maintenance time of each motor;

[0041] The specifications of each marked motor are compared with the specifications of each motor, and each motor whose specification difference with each marked motor is less than the preset specification difference is taken as a first-screen motor, and the average environmental data of the corresponding configuration position of each marked motor is compared with the safe operating environment data range of each first-screen motor. If the average environmental data of the corresponding configuration position of a marked motor is within the safe operating environment data range of a certain screening motor, then the first-screen motor is taken as the second-screen motor of the marked motor, thereby obtaining each second-screen motor of each marked motor.

[0042] Among them, the preset specification difference is set by the industrial equipment engineer.

[0043] Extract the reference life, maximum number of failures, average actual life, average number of failures, average maintenance time and price of each marked motor corresponding to each second screen motor, calculate the priority value of each marked motor corresponding to each second screen motor, and select the second screen motor with the first priority value as the backup motor of each marked motor.

[0044] In the above, the priority value of each marked motor corresponding to each second screen motor is calculated as follows: the reference life, limit failure number, average actual life, average failure number, average maintenance time and price of each marked motor corresponding to each second screen motor are recorded as , , , , and , q represents the number corresponding to each marked motor, r represents the number of each second screen motor, and both q and r are positive integers.

[0045] Evaluate expressions using precedence values: , get the priority value of the qth marked motor corresponding to the rth second screen motor , where , They represent the reference maintenance time and reference price of the second screen motor respectively, e represents the natural constant, , are the proportional coefficient of the preset life and the proportional coefficient of the number of failures, respectively. , They are respectively the proportional coefficient of the preset maintenance time and the proportional coefficient of the price.

[0046] Among them, the reference maintenance time and reference price of the two-screen motor are calculated by averaging the average maintenance time and price of each marked motor corresponding to each two-screen motor.

[0047] It should be noted that the setting process of the proportional coefficient of maintenance time and the proportional coefficient of price is as follows: the average maintenance time of each marked motor corresponding to each second-screen motor is calculated by difference, and the maximum average maintenance time difference is selected as the maintenance time difference, and the minimum average maintenance time is selected as the reference maintenance time, and the maintenance time difference is divided by the reference maintenance time to obtain the maintenance time fluctuation value; similarly, the price of each marked motor corresponding to each second-screen motor is calculated by difference, the maximum price difference is selected as the price difference, and the minimum price is selected as the reference price, and the price difference is divided by the reference price to obtain the price fluctuation value; the maintenance time fluctuation value is divided by the sum of the maintenance time fluctuation value and the price fluctuation value to obtain the proportional coefficient of maintenance time, and the price fluctuation value is divided by the sum of the maintenance time fluctuation value and the price fluctuation value to obtain the proportional coefficient of price.

[0048] In another specific embodiment, the specific process of generating a motor maintenance order is as follows: extracting the operating data of each faulty motor, classifying each faulty motor, obtaining the fault type of each faulty motor, and obtaining the operating life, historical fault count, fault type of each historical fault, and maintenance time of each historical fault of each faulty motor from the historical monitoring records of the equipment motor, and then confirming the maintenance type of each faulty motor.

[0049] In the above, each faulty motor is classified as follows: various operating data are obtained from the operating data of each faulty motor, and various operating data safety intervals are obtained from the safe operating data intervals of each motor. When a certain operating data in a motor is not within the safety interval of the operating data, it indicates that the operating data of the motor is abnormal. Based on the fault types corresponding to the various operating data abnormalities stored in the motor fault monitoring system, the fault type of the motor is obtained, so as to classify each faulty motor.

[0050] For example: various operating data include vibration frequency and noise level, and the safe operating data range includes the vibration frequency safety range and the noise level safety range. When the vibration frequency in a motor is not within the vibration frequency safety range, it indicates that the vibration frequency of the motor is abnormal. The fault type corresponding to the abnormal vibration frequency stored in the motor fault monitoring system is a rotor imbalance fault, and the fault type of the motor is a rotor imbalance fault.

[0051] Among them: fault types include rotor imbalance fault and bearing fault, etc.

[0052] In the above, the maintenance type of each faulty motor is confirmed. The specific process is as follows: According to the running life and historical fault times of each faulty motor, the availability coefficient of each faulty motor is calculated. The availability coefficient contains values ​​of 1 and -1. When the availability coefficient is 1, it indicates that the availability of the faulty motor is large, otherwise it indicates that the availability is small.

[0053] The expression of the available coefficient is: , where , , , , They represent the availability factor, reference life, running life, limit fault times, and historical fault times of the a-th fault motor respectively. represents the preset available evaluation coefficient threshold, and the reference life and limit fault number of each faulty motor are obtained from the motor record. a represents the number of each faulty motor, and a is a positive integer.

[0054] In the above, the available evaluation coefficient threshold is used to judge the critical value of the availability of the faulty motor, which is set by the engineer of the industrial equipment. For example, in the expression The analysis result is the available evaluation coefficient of the a-th faulty motor. When the available evaluation coefficient of the a-th faulty motor is 8, the available evaluation coefficient threshold is 5, and 8>5, it indicates that the a-th faulty motor has a large proportion of service life and the number of failures, and the availability of the faulty motor is small.

[0055] According to the fault type of each historical fault of each faulty motor and the maintenance time of each historical fault, the maintenance impact coefficient of each faulty motor is calculated. The maintenance impact coefficient contains the values ​​of 1 and -1. When the maintenance cost coefficient is 1, it indicates that the impact of maintenance is small, otherwise it indicates that the impact of maintenance is large.

[0056] In the above, the specific process of calculating the maintenance impact coefficient of each faulty motor is as follows: the fault type corresponding to each faulty motor is compared with the fault type of each historical fault of each faulty motor. If the fault type is the same, the maintenance time of the historical fault is used as the reference maintenance time, thereby obtaining each maintenance time of each faulty motor, and performing average calculation. The result is used as the downtime of each faulty motor, and the permitted downtime of the industrial equipment is obtained from the equipment control center, recorded as T1, and the expression of the maintenance impact coefficient is used: , get the maintenance impact coefficient of the ath fault motor , where Indicates the downtime of the ath faulty motor.

[0057] When at least one of the availability coefficient and the maintenance impact coefficient of a faulty motor is -1, it indicates that the maintenance type of the faulty motor is to replace the motor. When the availability coefficient and the maintenance impact coefficient of a faulty motor are both 1, it indicates that the maintenance type of the faulty motor is to repair the motor, thereby confirming the maintenance type of each faulty motor.

[0058] The configuration position of each faulty motor whose maintenance type is motor replacement is obtained as each marked position, and the motor is replaced according to each faulty motor of the replacement motor to obtain the replacement motor at each marked position; then the configuration position of each faulty motor whose maintenance type is motor repair is extracted as each marked position; at the same time, the configuration position of each marked motor is extracted, recorded as each identified position, and according to the backup motor of each marked motor, the backup motor of each identified position is obtained.

[0059] Then import the replacement motors at each marked position, each annotated position, and the backup motors at each identified position into a preset motor maintenance order template to generate a motor maintenance order.

[0060] The execution monitoring module is used to collect the maintenance data of the maintenance personnel when they perform motor maintenance, monitor the maintenance status of the maintenance personnel, and perform corresponding monitoring operations.

[0061] In the above, the maintenance data includes images of the actual replacement motor at each marked position, the maintenance duration at each marked position, and actual images of the actual backup motor at each marked position.

[0062] In the above, each time the maintenance personnel perform motor maintenance, they need to enter the motor fault monitoring system through the user end, click to start maintenance, and enter the configuration position of the maintenance motor. After the maintenance is completed, take the motor image and upload it to the motor fault monitoring system. After the motor is maintained, the time from the start of maintenance to the completion of maintenance is used as the maintenance time, and each mark position and each identification position are compared with the configuration position of the motor maintained each time. If a mark position is the same as the configuration position of a motor maintained at a certain time, the motor image taken after the maintenance of the motor is completed is used as the image of the actual replacement motor at each mark position. Similarly, if a identification position is the same as the configuration position of a motor maintained at a certain time, the motor image taken after the maintenance of the motor is completed is used as the actual image of the actual backup motor at the identification position, so as to collect the maintenance data of the maintenance personnel.

[0063] In a specific embodiment, the maintenance status of the maintenance personnel is monitored, and the specific process is as follows: the image of the actual replacement motor at each marked position, the maintenance time of each marked position, and the actual image of the actual backup motor at each marked position are obtained from the maintenance data of the maintenance personnel.

[0064] Acquire the characteristic image of the replacement motor at each marked position and the characteristic image of the backup motor at each identified position from the motor fault monitoring system; and obtain the reference maintenance time at each marked position.

[0065] In the above, the downtime of the faulty motor in each marked position is extracted from the downtime of each faulty motor as a reference maintenance time. The maintenance time of each faulty motor in each marked position is extracted from the maintenance time of each faulty motor, the maintenance time of each faulty motor in each marked position is calculated, and the maximum time difference is selected as the allowable time difference of each marked position.

[0066] The images of the actual replacement motors at each marked position, the maintenance time at each marked position and the actual images of the actual backup motors at each marked position are respectively compared with the characteristic images of the replacement motors at each marked position, the reference maintenance time at each marked position and the characteristic images of the backup motors at each marked position to monitor the corresponding maintenance conditions of the maintenance personnel, including whether the replacement is abnormal, the maintenance is abnormal or the backup configuration is abnormal.

[0067] In the above, the image of the actual replacement motor at each marked position and the actual image of the actual backup motor at each identified position are respectively compared with the characteristic image of the replacement motor at each marked position and the characteristic image of the backup motor at each identified position through image comparison technology. If the image of the actual replacement motor at a certain marked position is different from the characteristic image of the replacement motor, then the corresponding maintenance situation of the maintenance personnel is abnormal replacement, otherwise the corresponding maintenance situation of the maintenance personnel is normal replacement; if the actual image of the actual backup motor at a certain identified position is different from the characteristic image of the backup motor, then the corresponding maintenance situation of the maintenance personnel is abnormal backup configuration, otherwise the corresponding maintenance situation of the maintenance personnel is normal backup configuration.

[0068] The maintenance time of each marked position is compared with the reference maintenance time. If the difference between the maintenance time of a marked position and the reference maintenance time is greater than the permitted time difference, it indicates that the corresponding maintenance situation of the maintenance personnel is abnormal maintenance; otherwise, it indicates that the corresponding maintenance situation of the maintenance personnel is normal maintenance.

[0069] When the maintenance situation corresponding to the maintenance personnel is replacement abnormality, a replacement abnormality prompt signal is displayed in the display; when the maintenance situation corresponding to the maintenance personnel is backup configuration abnormality, a backup configuration abnormality prompt signal is displayed in the display; when the maintenance situation corresponding to the maintenance personnel is repair abnormality, a repair abnormality prompt signal is displayed in the display.

[0070] The embodiment of the present invention collects the operating data of all motors in industrial equipment and analyzes whether each motor has a fault. When a fault occurs, it analyzes whether the faulty motor needs to be configured with a backup motor based on the location of the faulty motor. If configuration is required, a suitable backup motor is selected. The maintenance type is analyzed based on the operating data of each faulty motor, and a motor maintenance order is generated. When the maintenance personnel are performing maintenance, the maintenance personnel are monitored, thereby solving the shortcomings of motor fault monitoring in traditional technologies, improving the accuracy of motor fault monitoring and analysis results and the timeliness of fault discovery, reducing maintenance difficulty and cost, and selecting backup motors for locations where backup motors need to be configured. While reducing the cost of backup motors, the stability and safety of backup motor performance are improved. When a motor fails, it is quickly replaced to reduce the length of equipment downtime, thereby reducing production losses. In addition, the behavior of maintenance personnel is monitored to ensure the transparency of the maintenance process and the quality and effect of motor maintenance.

[0071] The above contents are merely examples and explanations of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the concept of the invention or exceed the scope defined in this specification, they shall all fall within the protection scope of the present invention.

Claims

1. A motor fault monitoring system for industrial Internet of Things, characterized in that: include: Motor monitoring module, server and execution monitoring module; The motor monitoring module is used to collect the operating data and environmental data of each motor in the industrial equipment and send it to the server; The server is used to receive the operation data of each motor, analyze whether each motor is faulty, and if at least one motor is faulty, record each faulty motor as a faulty motor, obtain the functional data and historical monitoring records of the equipment motor, analyze whether each faulty motor needs to be configured with a backup motor according to the environmental data of each faulty motor, and record each faulty motor that needs to be configured with a backup motor as a marked motor, select the backup motor corresponding to each marked motor, and then generate a motor maintenance order and send it to the maintenance personnel; The specific process of analyzing whether each faulty motor needs to be configured with a backup motor is as follows: Obtaining from the historical monitoring records of the equipment motors the configuration location of each faulty motor, each historical environmental data corresponding to each configuration location, the number of failures of each historical motor in each configuration location, each maintenance duration of each historical motor in each configuration location, and the actual life of each historical motor in each configuration location; Obtain the control tasks corresponding to the motors at each configuration position from the functional data of the equipment motors; Compare the control tasks corresponding to the motors at each configuration position with the key control task set set by the equipment control center. If the control task corresponding to the motor at a certain configuration position is the same as a key control task in the key control task set, it indicates that the category of the motor at the configuration position is a Class I motor. Otherwise, it indicates that the motor at the configuration position is a Class II motor, thereby obtaining the category of the motors at each configuration position; According to the environmental data corresponding to each faulty motor, the historical environmental data corresponding to each configuration position and the configuration position of each faulty motor, the environmental state coefficient of each configuration position is analyzed; the environmental state coefficient includes the values ​​of 1 and -1. When the environmental state coefficient of a certain configuration position is 1, it indicates that the environment of the configuration position is normal. When the environmental state coefficient of a certain configuration position is -1, it indicates that the environment of the configuration position is abnormal. Analyze the loss coefficient of the motor in each configuration position according to the number of failures of each historical motor in each configuration position, the maintenance duration of each historical motor in each configuration position, and the actual life of each historical motor in each configuration position; The loss coefficient contains values ​​of 1 and -1. When the loss coefficient of the motor in a certain configuration position is -1, it indicates that the motor in this configuration position is easy to be damaged. When the loss coefficient of the motor in a certain configuration position is 1, it indicates that the motor in this configuration position is not easy to be damaged. According to the type of motor at each configuration position, the environmental state coefficient of each configuration position, the loss coefficient of the motor in each configuration position and the configuration position of each faulty motor, determine whether each faulty motor needs to be configured with a backup motor; The specific process of analyzing the loss coefficient of the motor in each configuration position is as follows: The reference life and limit fault times of each historical motor in each configuration position are obtained from the motor records of the motor fault monitoring system, which are recorded as N ig and G ig , i represents the number of each configuration position, g represents the number of each historical motor, and both i and g are positive integers; The maintenance time of each historical motor in each configuration position is accumulated to obtain the total maintenance time of each historical motor in each configuration position, which is recorded as T ig ; The expression of the loss coefficient analysis model is: Get the loss coefficient β of the motor in the i-th configuration position i , where f represents the total number of historical motors, N i ' g , G i ' g They represent the actual life and number of failures of the g-th historical motor in the i-th configuration position, respectively; T represents the average life of the historical motor; ε1 and ε2 are the preset proportional coefficients of life and number of failures, respectively; and χ is the preset reference loss assessment coefficient; The specific process of confirming whether each faulty motor needs to be equipped with a backup motor is as follows: According to the configuration position of each faulty motor, the category of each faulty motor is obtained; if the category of a faulty motor is a class I motor, and at least one of the environmental state coefficient and the loss coefficient of the configuration position corresponding to the faulty motor is -1, it indicates that the faulty motor needs to be configured with a backup motor; if the environmental state coefficient and the loss coefficient of the configuration position corresponding to the faulty motor are both 1, it indicates that the faulty motor does not need to be configured with a backup motor; If the category of a faulty motor is a Class II motor, and the environmental state coefficient and loss coefficient of the corresponding configuration position of the faulty motor are both -1, it indicates that the faulty motor needs to be configured with a backup motor; if at least one of the environmental state coefficient and loss coefficient of the corresponding configuration position of the faulty motor is 1, it indicates that the faulty motor does not need to be configured with a backup motor, so as to confirm whether each faulty motor needs to be configured with a backup motor; The execution monitoring module is used to collect the maintenance data of the maintenance personnel when they perform motor maintenance, monitor the maintenance status of the maintenance personnel, and perform corresponding monitoring operations.

2. The motor fault monitoring system of the industrial Internet of Things according to claim 1 is characterized in that: The specific process of analyzing whether each motor is faulty is as follows: The safe operation data interval of each motor is obtained from the equipment control center, and the operation data of each motor is compared with its corresponding safe operation data interval. If the operation data of a motor is not within its corresponding safe operation data interval, it indicates that the motor is faulty. Otherwise, it indicates that the motor is not faulty. In this way, whether each motor is faulty is analyzed.

3. The motor fault monitoring system of the industrial Internet of Things according to claim 1 is characterized in that: The specific process of analyzing the environmental state coefficient of each configuration position is as follows: Obtain the reference environmental operation data interval of the industrial equipment from the equipment control center, obtain the environmental data of each configuration location based on the environmental data and configuration location corresponding to each faulty motor, and calculate the average value with the historical environmental data corresponding to each configuration location to obtain the average environmental data of each configuration location; Analyze the model expression according to the environmental state: Get the environmental state coefficient α of the i-th configuration position i , where H i represents the average environmental data of the i-th configuration position, H′ represents the reference environmental operation data interval of the industrial equipment, i represents the number of each configuration position, and i is a positive integer.

4. The motor fault monitoring system of the industrial Internet of Things according to claim 1 is characterized in that: The specific process of selecting the backup motor corresponding to each marked motor is as follows: Obtain the specifications of each marked motor, extract the usage parameters and prices of each motor in the motor fault monitoring system, and obtain the specifications, safe operating environment data range, reference life and limit fault times from the usage parameters of each motor; Compare each motor with each historical motor in each configuration position. If a motor is the same as a historical motor in a configuration position, the actual life, number of failures and total maintenance time of the historical motor are used as the actual life, number of failures and total maintenance time of the motor, so as to obtain the actual life, number of failures and total maintenance time of each motor, and perform mean calculation to obtain the average actual life, average number of failures and average maintenance time of each motor; The specification of each marked motor is compared with the specification of each motor, and each motor whose specification difference with each marked motor is less than the preset specification difference is used as each first-screen motor, and the average environmental data of the corresponding configuration position of each marked motor is compared with the safe operating environment data interval of each first-screen motor. If the average environmental data of the corresponding configuration position of a certain marked motor is within the safe operating environment data interval of a certain screening motor, the first-screen motor is used as the second-screen motor of the marked motor, thereby obtaining each second-screen motor of each marked motor; Extract the reference life, maximum number of failures, average actual life, average number of failures, average maintenance time and price of each marked motor corresponding to each second screen motor, calculate the priority value of each marked motor corresponding to each second screen motor, and select the second screen motor with the first priority value as the backup motor of each marked motor.

5. The motor fault monitoring system of industrial Internet of Things according to claim 4 is characterized in that: The specific process of calculating the priority value of each marked motor corresponding to each second screen motor is as follows: The reference life, limit failure times, average actual life, average failure times, average maintenance time and price of each marked motor corresponding to each second screen motor are recorded as N qr , G qr 、N q ' r , G q ' r , T q ' r and D qr , q represents the number corresponding to each marked motor, r represents the number of each second screen motor, and both q and r are positive integers; Evaluate expressions using precedence values: Get the priority value δ of the qth marked motor corresponding to the rth second screen motor qr In the formula, T′ and D represent the reference maintenance time and reference price of the two-screen motor respectively, e represents the natural constant, ε1 and ε2 are the proportional coefficients of the preset life and the proportional coefficients of the number of failures respectively, and η1 and η2 are the proportional coefficients of the preset maintenance time and the proportional coefficients of the price respectively.

6. The motor fault monitoring system of industrial Internet of Things according to claim 1 is characterized in that: The specific process of generating a motor maintenance order is as follows: Extract the operating data of each faulty motor, classify each faulty motor, obtain the fault type of each faulty motor, and obtain the operating life, historical fault count, fault type of each historical fault, and maintenance time of each historical fault of each faulty motor from the historical monitoring records of the equipment motor, and then confirm the maintenance type of each faulty motor; The configuration positions of each faulty motor whose maintenance type is motor replacement are obtained as each marked position, and the motors are replaced according to each faulty motor of the replacement motor to obtain the replacement motors at each marked position; then, the configuration positions of each faulty motor whose maintenance type is motor repair are extracted as each marked position; at the same time, the configuration positions of each marked motor are extracted and recorded as each marked position, and the backup motors of each marked motor are obtained according to the backup motors of each marked motor; Then import the replacement motors at each marked position, each annotated position, and the backup motors at each identified position into a preset motor maintenance order template to generate a motor maintenance order.

7. The motor fault monitoring system of industrial Internet of Things according to claim 6 is characterized in that: The specific process of monitoring the maintenance status of the maintenance personnel is as follows: Obtaining from the maintenance personnel's maintenance data an image of the actual replacement motor at each marked location, the maintenance duration at each marked location, and an actual image of the actual backup motor at each marked location; Acquire a characteristic image of the replacement motor at each marked position and a characteristic image of the backup motor at each marked position from the motor fault monitoring system; And obtain the reference maintenance time of each marked position; The images of the actual replacement motors at each marked position, the maintenance time at each marked position and the actual images of the actual backup motors at each marked position are respectively compared with the characteristic images of the replacement motors at each marked position, the reference maintenance time at each marked position and the characteristic images of the backup motors at each marked position to monitor the corresponding maintenance conditions of the maintenance personnel, including whether the replacement is abnormal, the maintenance is abnormal or the backup configuration is abnormal.

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