Multifunctional monitoring system for engineering machinery and monitoring equipment thereof

Abstract

The embodiment of the invention discloses a multifunctional monitoring system for engineering machinery and monitoring equipment thereof, and belongs to the technical field of mechanical monitoring, and the system comprises a signal monitoring module which is used for being installed on target equipment, carrying out signal monitoring, and obtaining various mechanical signals; the data acquisition module is used for acquiring and processing the signal monitored by the signal monitoring module and forwarding the signal; the terminal server is used for receiving the signal data forwarded by the data acquisition module and carrying out data analysis, fault diagnosis and result display, and meanwhile, a 5G private network is arranged. The embodiment of the invention can predict and early warn faults and abrasion of equipment, so that safety accidents and property loss caused by unplanned shutdown and malignant faults are avoided, and the service life of the equipment is prolonged. Through visualization processing of vibration signal waveforms, impact components in cylinder cover vibration signals and periodic characteristics of the signals can be used for predictive maintenance of an engine, and the service life of the engine is prolonged.

Description

Technical Field

[0001] The present application belongs to the technical field of mechanical monitoring, and specifically, relates to a multifunctional monitoring system and monitoring equipment for engineering machinery. Background Art

[0002] The monitoring system for the engine of construction machinery should have the function of monitoring the dust in the intake air. Under the premise of not causing any negative impact on the engine, it can monitor and diagnose the dust pollution in the engine intake air, realize the warning, alarm and timely disposal of the intake pollution condition, so as to make the air entering the engine clean and control the dust pollution. At the same time, it should have the function of vibration monitoring, monitor and analyze the vibration data of the engine camshaft, warn and alarm the abnormal situation of the vibration data and provide real-time synchronous feedback to the maintenance personnel, so as to facilitate the fault diagnosis and rapid disposal, avoid serious damage to the engine to the greatest extent, and reduce the production loss caused by equipment downtime.

[0003] However, the existing monitoring system is difficult to conduct real-time online vibration monitoring and intake system dust monitoring, and cannot control the operating status of the monitored object in real time. It is impossible to predict and warn of equipment failures and wear, which may cause unplanned downtime and serious failures, resulting in safety accidents and property losses, and reducing the service life of the engine. Summary of the invention

[0004] In order to solve the above problems and technical defects, the embodiment of the present application adopts the following technical solution, a multifunctional monitoring system for engineering machinery, comprising:

[0005] A signal monitoring module is used to be installed on the target equipment to perform signal monitoring and obtain various mechanical signals;

[0006] The data acquisition module is used to collect and process the signals monitored by the signal monitoring module and to forward the signals;

[0007] The terminal server is used to receive signal data forwarded by the data acquisition module, perform data analysis, fault diagnosis and result display, and is also equipped with a 5G private network.

[0008] Preferably, the signal monitoring module includes wireless sensors and wired sensors. The wireless sensors use ZigBee and NBIoT sensors, and the wired sensors use vibration, temperature, noise, pressure, strain, flow, slow change, current and voltage sensors.

[0009] Furthermore, the data acquisition module includes an intelligent high-speed data collector, a data processor, a 5G signal module and a signal generator.

[0010] Furthermore, the wireless sensor and the wired sensor are both installed on the cylinder head bolts by means of threads, the intelligent high-speed data acquisition device is installed on the roof crossbeam by means of bolts at the four corners, and the wireless sensor and the wired sensor use four-core armored signal cables to transmit signals to the intelligent high-speed data acquisition device.

[0011] Furthermore, the data processor adopts a multi-working condition full-information intelligent data processor with dual network ports to process the collected signals. The data acquisition modules are connected through the terminals of the data processor, and data is sent through the 5G signal module and the 5G private network connection with the terminal server. The signal generator can automatically detect acceleration, speed, displacement and circuit operation status. The 5G signal module has a continuous recording and broadcasting detection function, and uploads data once every preset time.

[0012] Furthermore, the data processor has a network disconnection and resumption detection function. When the network is interrupted, the data that failed to be uploaded is automatically saved. When the network resumes communication, the data that failed to be uploaded is preferentially retransmitted. The memory of the data processor is greater than 2GB.

[0013] Preferably, the terminal server performs statistical analysis on the time domain signal to obtain time domain characteristic parameters, uses dimensional indicators to perform fault analysis, and obtains the operating status results of the target device under test, thereby determining whether the results are related to the fault, rotation speed and load.

[0014] Furthermore, the terminal server has real-time data monitoring, analysis and alarm functions, and has a real-time data overview page. The monitoring data can be transmitted back and displayed in real time. The real-time data overview page has the ability to refresh and display data in seconds, and abnormal data is automatically marked with different colors for distinction; for equipment measurement points that monitor real-time alarms, the alarm history data of the measurement point can be directly displayed.

[0015] Furthermore, the terminal server also has a real-time alarm function for abnormal data. After detecting abnormal data, it can issue a sound alarm signal in real time and push the abnormal data in real time. There are multiple alarm thresholds. Different alarm thresholds are set according to different rotation speeds and different working conditions of different target devices. Corresponding alarm states are set according to different alarm thresholds. Different alarm states are displayed in the system with different color labels.

[0016] A multifunctional monitoring device for engineering machinery comprises a memory, a processor and a computer program stored in the memory and executable on the processor. When the processor executes the program, the module contents of the multifunctional monitoring system for engineering machinery are realized.

[0017] Compared with the prior art, the beneficial effects of the embodiments of the present application are:

[0018] (1) This application utilizes sensor technology, data acquisition technology, communication technology and a big data management platform to conduct online vibration monitoring and intake system dust monitoring, which can not only control the operating status of the monitored object in real time, but also predict the development trend of the equipment, predict and warn of equipment failures and wear, avoid unplanned downtime and malignant failures, cause safety accidents and property losses, and extend the service life of the engine;

[0019] (2) This application uses a sensor to be installed by means of an adapter base or a magnetic base and industrial glue. At the same time, to ensure the integrity of the equipment, the sensor installation must not damage the structure of the equipment and related accessories. The acquisition cards are connected through terminals to meet the needs of collecting various signal data. The system has a wealth of professional graphs and can display various graphs on the same page without switching jumps. The time and value of each characteristic value at any time point can be displayed by dragging the time axis of the trend chart;

[0020] (3) The present application can achieve effective vibration measurement by setting a vibration sensor near the engine cylinder head. By combining the cylinder head vibration with the cylinder failure form analysis, it can be obtained that the vibration performance of the cylinder piston and other related structures when a failure occurs, and the waveform of the cylinder head vibration signal within a certain sampling time. After visual processing of the vibration signal waveform, the impact component in the cylinder head vibration signal and the periodic characteristics of the signal can be used to perform predictive maintenance on the engine. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In the attached picture:

[0022] Figure 1 Schematic diagram of the system structure of an embodiment of the present application. DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions 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 part of the embodiments of the present application, not all of the embodiments. Generally, the components of the embodiments of the present application described and shown in the drawings here can be arranged and designed in various different configurations.

[0024] Example 1

[0025] like Figure 1 As shown, a multifunctional monitoring system and monitoring equipment for engineering machinery, comprising:

[0026] A signal monitoring module is used to be installed on the target equipment to perform signal monitoring and obtain various mechanical signals;

[0027] The data acquisition module is used to collect and process the signals monitored by the signal monitoring module and to forward the signals;

[0028] The signal monitoring module includes wireless sensors and wired sensors. The wireless sensors use ZigBee and NBIoT sensors, and the wired sensors use vibration, temperature, noise, pressure, strain, flow, slow change, current and voltage sensors.

[0029] The data acquisition module includes an intelligent high-speed data logger, a data processor, a 5G signal module and a signal generator.

[0030] Both wireless sensors and wired sensors are installed on the cylinder head bolts with threads, and the intelligent high-speed data acquisition device is installed on the roof beam with bolts at the four corners. Wireless sensors and wired sensors use four-core armored signal cables to transmit signals to the intelligent high-speed data acquisition device.

[0031] The data processor adopts a multi-condition full-information intelligent data processor with dual network ports to process the collected signals. The data acquisition modules are connected through the terminals of the data processor, and the data is sent through the 5G signal module and the 5G private network connection with the terminal server. The signal generator can automatically detect the acceleration, speed, displacement and circuit operation status. The 5G signal module has a continuous recording and broadcasting detection function, and uploads data once every preset time.

[0032] The data processor has the function of resuming transmission after network disconnection. When the network is interrupted, it automatically saves the data that failed to be uploaded. When the network resumes communication, the data that failed to be uploaded will be retransmitted first. The memory of the data processor is greater than 2G.

[0033] The terminal server is used to receive signal data forwarded by the data acquisition module, perform data analysis, fault diagnosis and result display, and is also equipped with a 5G private network.

[0034] The terminal server performs statistical analysis on the time domain signal to obtain the time domain characteristic parameters, and uses dimensional indicators to perform fault analysis to obtain the operating status results of the target device under test, thereby determining whether the results are related to the fault, speed and load.

[0035] The terminal server has the functions of real-time data monitoring, analysis and alarm, and a real-time data overview page. The monitoring data can be transmitted back and displayed in real time. The real-time data overview page has the ability to refresh and display data within seconds, and abnormal data is automatically marked with different colors for distinction. For equipment measurement points that monitor real-time alarms, the alarm history data of the measurement point can be directly displayed.

[0036] The terminal server also has a real-time alarm function for abnormal data. After detecting abnormal data, it can issue a sound alarm signal in real time and push the abnormal data in real time. It has multiple alarm thresholds. Different alarm thresholds are set according to different speeds and different working conditions of different target equipment. The corresponding alarm status is set according to different alarm thresholds. Different alarm statuses are displayed in the system with different color labels.

[0037] The system supports the comparative analysis of massive graphs. On the same monitoring interface, it can simultaneously display the values, amplitudes, time domain graphs, frequency domain graphs, time three-dimensional spectra, speed three-dimensional spectra, Bode diagrams, trend graphs, axis trajectory graphs, axis position graphs, Nyquist graphs, power spectra, power spectrum density and other information of any number of units (at least 10 units) and any number of measuring points (at least 20 measuring points), and directly conduct comparative analysis without opening multiple pages for analysis; the system has a wealth of professional graphs, which can display various graphs on the same page without switching jumps, and has but is not limited to trends The system can analyze various basic graphs, such as graphs, spectrum graphs, time domain graphs, axis trajectory graphs, axis position graphs, waterfall graphs, Bode graphs, Nyquist graphs, etc. The system has the linkage analysis function of various graphs, and provides any combination and linkage analysis of vibration signals, component characteristics, rotation speed, process quantities, and electrical parameters. Users can display and compare the characteristic values ​​of any number of equipment and any number of measuring points and various professional graphs on the same page. The time axis of the trend graph can be dragged to display the time and value of each characteristic value at any time point, and other graphs can synchronously display the graphics at that time point.

[0038] The method of transforming the vibration signal in the time domain to form the frequency of the reaction period is called frequency domain analysis. The mathematical basis of this method is Fourier transform (FT) or fast Fourier transform (FFT). Compared with the time domain waveform diagram that represents the relationship between amplitude and time, the spectrum diagram represents the relationship between amplitude and frequency.

[0039] In practical applications, signals are often discrete in the time domain and frequency domain, so the discrete Fourier transform (DFT) is often used. Considering the operation speed and system consumption, the fast Fourier transform (FFT) is widely used in the frequency domain analysis of signals.

[0040] The system has a real-time monitoring function, and the monitoring data can display the value, graph and abnormal level in real time. It supports the comparative analysis of a large number of graphs, and can simultaneously display the values ​​and various graphs of multiple units and any measuring points on the same monitoring interface. It can also display all the graphs of a measuring point in a centralized manner for direct comparative analysis without opening multiple pages for analysis, thus achieving a quick insight into the status of components.

[0041] Historical data overview: You can select data from a previous time period to view historical data.

[0042] Example 2

[0043] A multifunctional monitoring device for engineering machinery comprises a memory, a processor and a computer program stored in the memory and executable on the processor. When the processor executes the program, the module contents of the multifunctional monitoring system for engineering machinery described in Example 1 are implemented.

[0044] The above-mentioned embodiments only express the preferred implementation methods of the present application, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the present application. It should be pointed out that, for ordinary technicians in this field, several modifications, improvements and substitutions can be made without departing from the concept of the present application, and these all belong to the protection scope of the present application.

Claims

1. A multifunctional monitoring system for construction machinery, characterized in that: include: A signal monitoring module is installed on the target equipment to monitor the signal and obtain various mechanical signals; The data acquisition module is used to collect and process the signals monitored by the signal monitoring module and to forward the signals; The terminal server is used to receive signal data forwarded by the data acquisition module, perform data analysis, fault diagnosis and result display, and is also equipped with a 5G private network.

2. A multifunctional monitoring system for construction machinery according to claim 1, characterized in that: The signal monitoring module includes wireless sensors and wired sensors. The wireless sensors use ZigBee and NBIoT sensors, and the wired sensors use vibration, temperature, noise, pressure, strain, flow, slow change, current and voltage sensors.

3. A multifunctional monitoring system for engineering machinery according to claim 2, characterized in that: The data acquisition module includes an intelligent high-speed data collector, a data processor, a 5G signal module and a signal generator.

4. A multifunctional monitoring system for engineering machinery according to claim 3, characterized in that: The wireless sensor and the wired sensor are both installed on the cylinder head bolts by means of threads, and the intelligent high-speed data acquisition device is installed on the roof crossbeam by means of bolts at the four corners. The wireless sensor and the wired sensor use four-core armored signal lines to transmit signals to the intelligent high-speed data acquisition device.

5. A multifunctional monitoring system for construction machinery according to claim 4, characterized in that: The data processor adopts a multi-working condition full-information intelligent data processor with dual network ports to process the collected signals. The data acquisition modules are connected through the terminals of the data processor, and the data is sent through the 5G signal module and the 5G private network connection with the terminal server. The signal generator can automatically detect the acceleration, speed, displacement and circuit operation status. The 5G signal module has a continuous recording and broadcasting detection function, and uploads data once every preset time.

6. A multifunctional monitoring system for construction machinery according to claim 5, characterized in that: The data processor has a network disconnection and resumption detection function. When the network is disconnected, it automatically saves the data that failed to be uploaded. When the network resumes communication, the data that failed to be uploaded is preferentially retransmitted. The memory of the data processor is greater than 2GB.

7. The multifunctional monitoring system for engineering machinery according to claim 1, characterized in that: The terminal server performs statistical analysis on the time domain signal to obtain time domain characteristic parameters, uses dimensioned indicators to perform fault analysis, and obtains the operating status results of the target device under test, thereby determining whether the results are related to the fault, rotation speed and load.

8. A multifunctional monitoring system for engineering machinery according to claim 7, characterized in that: The terminal server has the functions of real-time data monitoring, analysis and alarm, and has a real-time data overview page. The monitoring data can be transmitted back and displayed in real time. The real-time data overview page has the ability to refresh and display data in seconds, and abnormal data is automatically marked with different colors for distinction. For equipment measurement points that monitor real-time alarms, the alarm history data of the measurement point can be directly displayed.

9. A multifunctional monitoring system for engineering machinery according to claim 8, characterized in that: The terminal server also has a real-time alarm function for abnormal data. After detecting abnormal data, it can issue a sound alarm signal in real time and push the abnormal data in real time. It has multiple alarm thresholds. Different alarm thresholds are set according to different rotation speeds and different working conditions of different target devices. Corresponding alarm states are set according to different alarm thresholds. Different alarm states are displayed in the system with different color labels.

10. A multifunctional monitoring device for construction machinery, comprising a memory, a processor and a computer program stored in the memory and executable on the processor, characterized in that: When the processor executes the program, the module content of the multifunctional monitoring system for engineering machinery according to any one of claims 1 to 9 is implemented.

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