Hydraulic station monitoring system

Abstract

The embodiment of the invention provides a hydraulic station monitoring system, and relates to the technical field of hydraulic station management, the hydraulic station monitoring system comprises an online monitoring platform and a data acquisition and processing module; the data acquisition and processing module is in communication connection with the on-line monitoring platform, and the data acquisition and processing module is used for acquiring operation parameters of equipment on each production line in the hydraulic station and transmitting the operation parameters to the on-line monitoring platform; and the on-line monitoring platform is used for generating a real-time monitoring picture for the information state of the equipment on each production line in an aerial view form based on the operation parameters, and the problem of predictive maintenance of the hydraulic system can be solved by monitoring the equipment on each production line in the hydraulic station in real time.

Description

Technical Field

[0001] The present application relates to the technical field of hydraulic station management, and in particular to a hydraulic station monitoring system. Background Art

[0002] With the continuous development of modern mass production and the continuous progress of science and technology, in order to maximize production efficiency and product quality, multiple production lines and multiple equipment often need to run for a long time and at the same time, which in disguise increases the potential possibility of equipment failure and the type of failure. Once the equipment fails, it may cause serious or even catastrophic consequences, especially in the industrial environment of hydraulic stations. Therefore, how to monitor hydraulic equipment online is an important measure to ensure the normal operation of hydraulic stations. Summary of the invention

[0003] An embodiment of the present application provides a hydraulic station monitoring system, which can solve the problem of predictive maintenance of the hydraulic system by monitoring each production line equipment in the hydraulic station in real time.

[0004] The above hydraulic station monitoring system includes an online monitoring platform and a data acquisition and processing module;

[0005] The data acquisition and processing module is in communication connection with the online monitoring platform, and the data acquisition and processing module is used to collect the operating parameters of the equipment on each production line in the hydraulic station and transmit the operating parameters to the online monitoring platform;

[0006] The online monitoring platform is used to generate a real-time monitoring screen for the information status of the equipment on each production line in the form of a bird's-eye view based on the operating parameters.

[0007] In some embodiments, the hydraulic station monitoring system further includes a basic data module;

[0008] The basic data module is respectively communicated with the data acquisition and processing module and the online monitoring platform. The basic data module is used to forward and store the operating parameters, and is also used to manage the operating data of the hydraulic station. The operating data includes information and historical data of the collection point, gateway information, hydraulic station information and branch factory information.

[0009] In some embodiments, the hydraulic station monitoring system further includes an alarm module;

[0010] The alarm module is communicatively connected to the basic data module and the online monitoring platform respectively. The alarm module is used to set alarm limits based on the operating parameters of the equipment on each production line, and to issue an alarm on the online monitoring platform based on the alarm limits. The operating parameters include operating conditions and process requirements. The upper and lower limits of the alarm limits are related to the historical data stored in the basic data module.

[0011] In some embodiments, the alarm module is also used to establish an expert model based on the data stored in the basic data module, and the expert model includes multiple hydraulic station health evaluation models. The hydraulic station health evaluation model is used to generate prediction data based on the operating data of the hydraulic station, and the expert model is used to evaluate the health of the hydraulic station based on the prediction data of the multiple hydraulic station health evaluation models.

[0012] In some embodiments, the multiple hydraulic station health assessment models include:

[0013] Servo hydraulic station contamination warning model, used to predict the contamination level and life of hydraulic oil;

[0014] A hydraulic station anti-oil leakage warning model, used to predict the leakage rate of the hydraulic oil;

[0015] The hydraulic station thermal imaging early warning model is used to monitor the ambient temperature of the hydraulic station, the temperature of the hydraulic oil pipeline, the temperature of the equipment on each production line, and to issue an early warning based on the monitored temperature.

[0016] In some embodiments, the alarm module is further used to generate an intelligent diagnosis report based on the health of the hydraulic station, and to generate a fault alarm and a fault warning on the online monitoring platform based on the intelligent diagnosis report.

[0017] In some embodiments, the hydraulic station monitoring system further includes an automatic intelligent inspection module;

[0018] The automatic intelligent inspection module is in communication connection with the basic data module, and is used to generate inspection records based on the inspection cycle of the hydraulic station, wherein the inspection records include operating parameters of the equipment that needs to be inspected in each inspection cycle.

[0019] In some implementations, the operating parameters of the equipment on each production line are collected from an on-site HMI interface, an oil analyzer, a motor current transformer, and a thermal imaging camera based on the type of equipment.

[0020] In some embodiments, the data acquisition and processing module includes a hydraulic edge server and a video server; the basic data module includes a database server, and the database server is respectively connected to the hydraulic edge server and the video server in communication;

[0021] The data collected by the on-site HMI interface, the oil analyzer and the motor current transformer are sent to the hydraulic edge server to form the operating parameters;

[0022] The data collected by the thermal imaging camera is sent to the video server to form the operating parameters.

[0023] In some embodiments, the online monitoring platform generates real-time monitoring images of thermal imaging temperature measurement, oil contamination, and motor current of the equipment on each production line based on the operating parameters received by the database server.

[0024] The hydraulic station monitoring system provided in the embodiment of the present application includes an online monitoring platform and a data acquisition and processing module; the data acquisition and processing module is in communication connection with the online monitoring platform, and the data acquisition and processing module is used to collect the operating parameters of the equipment on each production line in the hydraulic station and transmit the operating parameters to the online monitoring platform; the online monitoring platform is used to generate a real-time monitoring screen for the information status of the equipment on each production line in the form of a bird's-eye view based on the operating parameters. The above-mentioned hydraulic station monitoring system collects the operating parameters of the equipment on each production line in the hydraulic station through the data acquisition and processing module, and generates a real-time monitoring screen for the information status of the equipment on each production line in the form of a bird's-eye view based on the online monitoring platform, which can quickly discover whether there is a risk of failure of individual equipment, thereby solving the problem of predictive maintenance of the hydraulic system. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solution of the present application, the drawings required for use in the embodiments are briefly introduced below. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0026] Figure 1 A structural schematic diagram of a hydraulic station monitoring system provided in an embodiment of the present application;

[0027] Figure 2 An architectural diagram of a hydraulic station monitoring system provided in an embodiment of the present application. DETAILED DESCRIPTION

[0028] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present application.

[0029] It should be understood that the "plurality" mentioned in this article refers to two or more. In the description of the embodiments of the present application, unless otherwise specified, " / " means or, for example, A / B can mean A or B; "and / or" in this article is only a description of the association relationship of associated objects, indicating that there can be three relationships, for example, A and / or B can mean: A exists alone, A and B exist at the same time, and B exists alone. In addition, in order to facilitate the clear description of the technical solutions of the embodiments of the present application, in the embodiments of the present application, the words "first", "second" and so on are used to distinguish between the same items or similar items with basically the same functions and effects. Those skilled in the art can understand that the words "first", "second" and so on do not limit the quantity and execution order, and the words "first", "second" and so on do not limit certain different

[0030] In addition, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or apparatus that includes a series of steps or elements is not necessarily limited to those steps or elements explicitly listed, but may include other steps or elements not explicitly listed or inherent to such process, method, product, or apparatus.

[0031] In view of the current modularization and black-boxing of hydraulic equipment functions, the present application provides a hydraulic station monitoring system that integrates the operating status and mechanism of hydraulic equipment with information technology to monitor the hydraulic equipment on each production line in the hydraulic station, thereby solving the problem of predictive maintenance of the hydraulic system. Figure 1 , Figure 1 A schematic diagram of the structure of a hydraulic station monitoring system provided in an embodiment of the present application:

[0032] The above-mentioned hydraulic station monitoring system includes a data acquisition and processing module 100 and an online monitoring platform 200, wherein the data acquisition and processing module 100 is communicatively connected with the online monitoring platform 200, and the data acquisition and processing module 100 is used to collect the operating parameters of the equipment on each production line in the hydraulic station and transmit the operating parameters to the online monitoring platform 200; the online monitoring platform 200 is used to generate a real-time monitoring screen for the information status of the equipment on each production line in the form of a bird's-eye view based on the operating parameters, and the above-mentioned information status may include parameters for reflecting the status of the equipment, body indicators, working conditions, etc.

[0033] Exemplarily, the data acquisition and processing module 100 can collect the operating parameters of the corresponding equipment by configuring appropriate sensors on the equipment on each production line. The operating parameters may include temperature, current, pressure, etc. based on the type of equipment, and are transmitted to the online monitoring platform 200 via a wireless network or a wired network connection.

[0034] The above-mentioned online monitoring platform 200 is used to display and monitor the operating status of the hydraulic station. Specifically, the operating parameters of the equipment on each production line transmitted by the data acquisition and processing module 100 generate a real-time monitoring screen for the information status of the equipment on each production line in the form of a bird's-eye view. The information status reflected in the real-time monitoring screen can change in real time with the operating parameters transmitted by the data acquisition and processing module 100, so that the on-site monitoring personnel can obtain the information status of the equipment on each production line in real time as a whole, so as to predict the operating risks of each equipment and reduce the maintenance cost of the hydraulic station.

[0035] Continue to refer Figure 1 In some examples, due to the large amount of collected data, in order to facilitate data management, a basic data module 300 can also be set in the above-mentioned data collection and processing module 100 and the online monitoring platform 200. The basic data module 300 can forward the operating parameters of the equipment transmitted by the data collection and processing module 100 to the above-mentioned online monitoring platform 200, and store the historical data of the above-mentioned operating parameters for subsequent analysis.

[0036] The basic data module 300 is also used to manage the operation data of the hydraulic station, which includes the information and historical data of the collection point, gateway information, hydraulic station information and branch factory information. The collection point refers to the point where production information is collected on each production line, the gateway refers to various network devices used for communication connection, and the hydraulic station information is the data related to all hydraulic stations in the entire company, including the hydraulic station code, name, and affiliated branch factory. The branch factory refers to a company's steel mill, iron mill and other units.

[0037] In some examples, such as Figure 2 As shown, Figure 2This is an architecture diagram of a hydraulic station monitoring system provided in an embodiment of the present application. The operating parameters of the equipment on each of the above-mentioned production lines can be collected from the on-site HMI interface, oil analyzer, motor current transformer and thermal imaging camera based on the type of equipment.

[0038] For example, the hydraulic station includes various types of hydraulic equipment, and each type of hydraulic equipment needs to monitor different types of parameters. For example, the oil analyzer can monitor the oil contamination, the thermal imaging camera can monitor the temperature information of various pipelines, oil tanks and various valves, the motor current transformer can monitor the motor current, and the on-site HMI (Human Machine Interface) can collect some on-site data through the PLC (Programmable Logic Controller), such as servo valve proportional valve signal, hydraulic cylinder magnetic scale signal, etc. Setting different collection methods based on the equipment type can improve the accuracy and focus of monitoring the hydraulic equipment, thereby improving the accuracy of monitoring the operating status of the hydraulic station.

[0039] Continue as Figure 2 As shown, the data acquisition and processing module 100 includes a hydraulic edge server and a video server; the basic data module 300 includes a database server, and the database server is respectively communicated with the hydraulic edge server and the video server; the data collected by the on-site HMI interface, the oil analyzer and the motor current transformer are sent to the hydraulic edge server to form operating parameters; the data collected by the thermal imaging camera is sent to the video server to form operating parameters.

[0040] Exemplarily, the hydraulic edge server and the video server are connected to the above-mentioned database server through a gateway to realize information interaction. An energy data acquisition network is constructed through the hydraulic edge server, a video network is constructed through the video server, and an L1 network is constructed through the PLC and the on-site HMI interface. The modular network form is convenient for maintenance and management.

[0041] Setting up a hydraulic edge server at a level close to the HMI interface, oil analyzer, and motor current transformer can reduce the delay of data transmission and prevent the loss of data collected through the HMI interface, oil analyzer, and motor current transformer, so that the operating parameters of the equipment on each production line can be more accurately transmitted to the database server of the basic data module 300, and the above-mentioned online monitoring platform 200 can also more accurately reflect the information status of the equipment. The data collected by the thermal imaging camera is sent to the video server. Considering that the thermal imaging camera collects image information and occupies a large amount of data, a separate video server can be set up for storage to prevent data loss due to insufficient server capacity.

[0042] The oil analyzer can be transmitted to the hydraulic edge server through the serial port server and the motor current transformer through the data collector. Each serial port server or data collector can be under the jurisdiction of multiple oil analyzers or motor current transformers, which can improve the concentration of collected data and reduce the pressure of on-site wiring. At the same time, some collection equipment such as oil analyzers can also be transmitted to PLC through the converter, and then transmitted from PLC to the hydraulic edge server.

[0043] In some examples, the database server can adopt a cloud server to reduce operating costs.

[0044] In some examples, the online monitoring platform 200 generates real-time monitoring images of thermal imaging temperature measurement, oil contamination, and motor current of equipment on each production line based on the operating parameters received by the above-mentioned database server.

[0045] Exemplarily, the online monitoring platform 200 generates a real-time monitoring screen (i.e. Figure 2 The real-time monitoring screen can display the equipment on each production line in the form of a circuit architecture diagram, and the periphery of the interface can display information and data on the operating status, namely, thermal imaging temperature measurement, oil contamination and motor current of the equipment on each production line. The display method can be numerical, curve or bar graph, so that maintenance personnel can monitor the hydraulic station as a whole.

[0046] Continue as Figure 1 As shown, according to some embodiments, the hydraulic station monitoring system further includes an alarm module 400, which is respectively communicated with the basic data module 300 and the online monitoring platform 200. The alarm module 400 is used to set alarm limits based on the operating parameters of the equipment on each production line, and to issue an alarm on the online monitoring platform 200 based on the alarm limits. The operating parameters include operating conditions and process requirements, and the upper and lower limits of the alarm limits are related to the historical data stored in the basic data module 300.

[0047] Exemplarily, the alarm module 400 sets corresponding alarm limits according to the operating parameters (such as pressure, flow, temperature, etc.) and process requirements of the equipment on the production line. The upper and lower limits of the alarm limit are related to the historical data stored in the basic output module. The historical data refers to the historical data of the operating parameters of the equipment on the above production line. For example, the upper and lower values ​​of the above alarm limit can be set according to the maximum and minimum values ​​of a certain oil pressure gauge in a longer period of time, so that the set threshold can be closer to the actual working situation. When the operating parameters of a certain equipment reach the above alarm limit, the alarm module 400 can issue an alarm through the online monitoring platform 200, and the alarm mode includes flashing, sound, etc.

[0048] In some examples, the alarm module 400 is also used to establish an expert model based on the data stored in the basic data module 300, the expert model includes a variety of hydraulic station health evaluation models, the hydraulic station health evaluation model is used to generate prediction data based on the operating data of the hydraulic station, and the expert model is used to evaluate the health of the hydraulic station based on the prediction data of the variety of hydraulic station health evaluation models.

[0049] Exemplarily, the expert model can be established by analyzing the historical operation data of the hydraulic station stored in the basic data module 300, which includes a variety of hydraulic station health evaluation models, each of which can reflect the operation of one aspect of the hydraulic station and generate predictive data for that aspect, such as a model reflecting the relationship between the power consumption and the operating life of the equipment. As the operating life of the equipment increases, the power consumption growth rate will become faster and faster. The model can generate predictive analysis on the relationship between power consumption and operating life based on historical data (equipment operating parameters, performance, working environment, etc.), thereby helping maintenance personnel to judge the future working conditions of the equipment. By comprehensively analyzing the indicators generated by various hydraulic station health evaluation models, the expert model can evaluate the health of the hydraulic station, and the evaluation method can adopt the trend curve method.

[0050] In some examples, the above-mentioned multiple hydraulic station health assessment models include: a servo hydraulic station contamination warning model, which is used to predict the contamination level and life of hydraulic oil. In a hydraulic station, the contamination of hydraulic oil is an important factor affecting system performance and life. By monitoring and analyzing the content of pollutants in hydraulic oil, the contamination level of hydraulic oil can be evaluated, thereby predicting the replacement cycle of hydraulic oil and the maintenance requirements of the system.

[0051] The hydraulic station anti-leakage early warning model is used to predict the leakage rate of hydraulic oil. The leakage of hydraulic oil will not only cause oil loss, but also may cause safety accidents. By monitoring the leakage of hydraulic oil, the leakage rate can be evaluated and the potential leakage risk can be predicted.

[0052] The hydraulic station thermal imaging early warning model is used to monitor the ambient temperature of the hydraulic station, the temperature of the hydraulic oil pipeline, and the temperature of the equipment on each production line, and to issue early warnings based on the monitored temperatures. Infrared thermal imaging technology can be used to monitor the temperature distribution on the surface of the equipment in real time, thereby detecting overheated or low-temperature areas, which may be early signs of failure. By analyzing thermal imaging data, the operating status of the equipment and potential failure risks can be predicted.

[0053] In some examples, the alarm module 400 is also used to generate an intelligent diagnosis report based on the health of the hydraulic station, and to generate a fault alarm and a fault warning on the online monitoring platform 200 based on the intelligent diagnosis report.

[0054] Exemplarily, the above-mentioned intelligent diagnostic report can quantitatively describe the current health status of the hydraulic station, and can predict potential failures and performance degradation of some equipment, thereby facilitating maintenance personnel to extract them for processing or maintenance, and can generate fault alarms and fault warnings based on whether the equipment has current failures or expected failures, and both fault alarms and fault warnings can be displayed on the online monitoring platform 200.

[0055] According to some embodiments, Figure 1 As shown, the above-mentioned hydraulic station monitoring system also includes an automatic intelligent inspection module 500; the automatic intelligent inspection module 500 is communicated with the basic data module 300, and the automatic intelligent inspection module 500 is used to generate inspection records based on the inspection cycle of the hydraulic station, and the inspection records include the operating parameters of the equipment that needs to be inspected in each inspection cycle.

[0056] For example, the inspection cycle may be different according to the requirements of different equipment and systems. The hydraulic station will generate different inspection cycles and corresponding requirements for different equipment on different production lines based on the different equipment and production lines. The automatic intelligent inspection module 500 can read the above inspection cycle and corresponding requirements from the basic data module 300, arrange and remind regular inspection work, and generate inspection records. The inspection records include the operating parameters of the equipment that needs to be inspected in each inspection cycle to facilitate maintenance personnel to handle the equipment.

[0057] Similar parts between the embodiments provided in this application can be referenced to each other. The specific implementation methods provided above are only a few examples under the general concept of this application and do not constitute a limitation on the protection scope of this application. For those skilled in the art, any other implementation methods expanded based on the scheme of this application without creative work belong to the protection scope of this application.

Claims

1. A hydraulic station monitoring system, characterized in that: Includes online monitoring platform and data acquisition and processing modules; The data acquisition and processing module is in communication connection with the online monitoring platform, and the data acquisition and processing module is used to collect the operating parameters of the equipment on each production line in the hydraulic station and transmit the operating parameters to the online monitoring platform; The online monitoring platform is used to generate a real-time monitoring screen for the information status of the equipment on each production line in the form of a bird's-eye view based on the operating parameters.

2. The system according to claim 1, characterized in that It also includes basic data modules; The basic data module is respectively communicated with the data acquisition and processing module and the online monitoring platform. The basic data module is used to forward and store the operating parameters, and is also used to manage the operating data of the hydraulic station. The operating data includes information and historical data of the collection point, gateway information, hydraulic station information and branch factory information.

3. The system according to claim 2, characterized in that It also includes an alarm module; The alarm module is communicatively connected to the basic data module and the online monitoring platform respectively. The alarm module is used to set alarm limits based on the operating parameters of the equipment on each production line, and to issue an alarm on the online monitoring platform based on the alarm limits. The operating parameters include operating conditions and process requirements. The upper and lower limits of the alarm limits are related to the historical data stored in the basic data module.

4. The system according to claim 3, characterized in that The alarm module is also used to establish an expert model based on the data stored in the basic data module, and the expert model includes multiple hydraulic station health evaluation models. The hydraulic station health evaluation model is used to generate prediction data based on the operating data of the hydraulic station, and the expert model is used to evaluate the health of the hydraulic station based on the prediction data of the multiple hydraulic station health evaluation models.

5. The system according to claim 4, characterized in that The various hydraulic station health assessment models include: Servo hydraulic station contamination warning model, used to predict the contamination level and life of hydraulic oil; A hydraulic station anti-oil leakage warning model, used to predict the leakage rate of the hydraulic oil; The hydraulic station thermal imaging early warning model is used to monitor the ambient temperature of the hydraulic station, the temperature of the hydraulic oil pipeline, the temperature of the equipment on each production line, and to issue an early warning based on the monitored temperature.

6. The system according to claim 5, characterized in that The alarm module is also used to generate an intelligent diagnosis report based on the health of the hydraulic station, and to generate a fault alarm and a fault warning on the online monitoring platform based on the intelligent diagnosis report.

7. The system according to claim 2, characterized in that It also includes an automatic intelligent inspection module; The automatic intelligent inspection module is in communication connection with the basic data module, and is used to generate inspection records based on the inspection cycle of the hydraulic station, wherein the inspection records include operating parameters of the equipment that needs to be inspected in each inspection cycle.

8. The system according to any one of claims 2 to 7, characterized in that The operating parameters of the equipment on each production line are collected from the on-site HMI interface, oil analyzer, motor current transformer and thermal imaging camera based on the type of equipment.

9. The system according to claim 8, characterized in that The data acquisition and processing module includes a hydraulic edge server and a video server; the basic data module includes a database server, and the database server is respectively connected to the hydraulic edge server and the video server in communication; The data collected by the on-site HMI interface, the oil analyzer and the motor current transformer are sent to the hydraulic edge server to form the operating parameters; The data collected by the thermal imaging camera is sent to the video server to form the operating parameters.

10. The system according to claim 9, characterized in that The online monitoring platform generates real-time monitoring images of thermal imaging temperature measurement, oil contamination and motor current of the equipment on each production line based on the operating parameters received by the database server.

Images