Industrial equipment maintenance system

Abstract

The invention relates to the technical field of industrial equipment maintenance, and discloses an industrial equipment maintenance system. The system comprises a data acquisition module, a data processing module, a state judgment module, a maintenance execution module and a maintenance optimization module. The technical problems that in the prior art, lubricating oil maintenance depends on fixed-period replacement, the state of lubricating oil cannot be dynamically monitored, and particularly under the conditions that the equipment operation environment is complex and the working condition changes frequently, the degradation degree of the lubricating oil cannot be accurately judged, and maintenance cannot be executed in time are solved. According to the invention, by collecting key data such as the viscosity, the particle concentration and the oxidation index of the lubricating oil in real time and combining cloud analysis and automatic maintenance, precise monitoring of the state of the lubricating oil and dynamic adjustment of the maintenance task are realized, so that the problem of resource waste caused by premature replacement or equipment damage caused by delayed maintenance is avoided, and the service life of the lubricating oil is prolonged. And the reliability and the maintenance efficiency of equipment operation are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of industrial equipment maintenance, and in particular relates to an industrial equipment maintenance system. Background Art

[0002] At present, the lubricant maintenance of industrial equipment mainly relies on fixed-cycle manual replacement or simple operation time timing maintenance, which has the problem of insufficient accuracy; for example, when the equipment operating environment is complex and the operating conditions change frequently, the fixed-cycle replacement of lubricants may lead to a waste of maintenance resources or equipment failure due to the failure to timely discover the deterioration of lubricants. The existing technology is difficult to monitor the key parameters such as the viscosity, particle concentration and oxidation index of lubricants in real time, and it is difficult to accurately judge the degree of deterioration of lubricants. It is also difficult to dynamically adjust the maintenance strategy according to the actual operating status, and it is unable to fully meet the needs of efficient and accurate maintenance in complex industrial scenarios. Therefore, there is an urgent need for an industrial equipment maintenance system that can monitor the deterioration state of lubricants in real time and dynamically generate maintenance instructions according to the specific operating conditions, so as to achieve accurate monitoring of lubricant status and optimal adjustment of maintenance tasks under complex operating conditions, thereby improving the reliability and maintenance efficiency of equipment operation. Summary of the invention

[0003] In view of the above-mentioned technical deficiencies, the purpose of the present invention is to propose an industrial equipment maintenance system, which aims to solve the technical problems in the prior art that lubricating oil maintenance relies on fixed-period replacement and cannot dynamically monitor the status of the lubricating oil, especially under conditions where the equipment operating environment is complex and the operating conditions change frequently, and it is impossible to accurately judge the degree of lubricating oil deterioration and perform maintenance in a timely manner.

[0004] In order to solve the above technical problems, the present invention adopts the following technical solution: The present invention provides an industrial equipment maintenance system, comprising:

[0005] Data acquisition module, used to collect lubricating oil status data of industrial equipment in real time through multiple types of sensors t , and the lubricating oil status data D t Transmitted to the preset gateway device; wherein the lubricating oil status data includes the lubricating oil viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t ;

[0006] The lubricating oil status data D t ={μ t ,C t ,O t}Transmit to the gateway device via Bluetooth or WiFi;

[0007] The data processing module is used to process the lubricating oil status data D using the preset gateway device. tPre-processing to obtain lubricating oil status data D t2 The pre-processed lubricant status data D is transmitted through the narrowband Internet of Things NB-loT t2 Upload to the cloud server; the preprocessing includes data calibration and data compression;

[0008] The status judgment module is used to check the lubricating oil status data D on the cloud server. t2 Perform cleaning analysis and calculate lubricant deterioration index I t ;

[0009] The calculation of lubricant deterioration index includes: comprehensive analysis of lubricant viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t , the formula is:

[0010] I t =w 1 ·μ t +w 2 ·C t +w 3 ·O t

[0011] Among them, I t is the lubricant degradation index of the lubricant at time t, w 1 ,w 2 ,w 3 They represent the weight coefficients of lubricant oil viscosity, lubricant oil particle concentration and lubricant oil oxidation index respectively;

[0012] Through the preset lubricant degradation index threshold I threshold Determine the running status of lubricating oil S t , S t The values ​​include normal and need to be replaced;

[0013] Maintenance execution module, used to t Generate maintenance instruction C t , maintenance instruction formula:

[0014]

[0015] If S t = normal, then generate a continue running instruction; if S t = If replacement is required, a lubricant replacement instruction is generated;

[0016] Maintaining Directive C through Narrowband Internet of Things NB-IoT t Send it to the device and perform maintenance operations, including:

[0017] If C t= Replace the lubricant, the automatic lubrication system will be triggered to replace the lubricant or remind the maintenance personnel to replace the lubricant. After the lubricant is replaced, the lubricant viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t Initialize to the preset standard range;

[0018] Maintenance optimization module, used to record and store lubricant historical status data history , the lubricating oil historical status data D history ={μ t ,C t ,O t ,I t}Stored in cloud server in timestamp sequence, based on historical status data D history Feedback adjustment of the weight coefficient w of the lubricant deterioration index 1 ,w 2 ,w 3 .

[0019] Preferably, in the data acquisition module, the lubricating oil status data includes:

[0020] Lubricating oil viscosity μ t , used to represent the dynamic fluidity of the lubricating oil at time t, in Pascals per second, collected by an online viscosity sensor;

[0021] Lubricating oil particle concentration C t , used to indicate the concentration of foreign particles in lubricating oil, in parts per million, collected by particle sensors;

[0022] Lubricating oil oxidation index O t , used to indicate the degree of oxidation of lubricating oil in percentage, collected by spectral analysis sensor.

[0023] Preferably, in the data collection module, a collection time interval Δt is set, and the collection time interval Δt is dynamically adjusted according to the equipment operation intensity, and the unit is hour, and the range is 1h≤Δt≤24h.

[0024] Preferably, in the data processing module, the data calibration process includes:

[0025] Lubricating oil status data D t Perform linear calibration, the formula is:

[0026]

[0027] in, is the lubricating oil state data after linear calibration, k is the calibration coefficient of the lubricating oil state data, and b is the bias term of the lubricating oil state data.

[0028] Preferably, in the position output module, in the data processing module, the data compression processing includes:

[0029] Using differential compression algorithm to process lubricating oil condition data after linear calibration The formula is:

[0030]

[0031] Among them, D t2 is the lubricating oil status data after pretreatment, It is the difference between the lubricating oil state data after linear calibration at the current time t and the previous time t-1.

[0032] Preferably, in the state judgment module, the cleaning analysis includes removing abnormal values ​​using a boundary detection algorithm. Then remove D t2 , where D min and D max They are respectively the upper and lower thresholds for safe operation of lubricating oil status data.

[0033] Preferably, in the state judgment module, the judgment formula for the running state of the lubricating oil is:

[0034]

[0035] Among them, S t It is the lubricating oil running state.

[0036] The beneficial effects of the present invention are as follows: compared with the prior art in which lubricant maintenance relies on fixed-period replacement and cannot dynamically monitor the state of the lubricant, especially under conditions where the equipment operating environment is complex and the operating conditions change frequently, the technical problem of being unable to accurately judge the degree of lubricant deterioration and perform maintenance in a timely manner is solved. Since the present application collects key data such as lubricant viscosity, particle concentration and oxidation index in real time, combined with cloud analysis and automated maintenance, it realizes accurate monitoring of the lubricant state and dynamic adjustment of maintenance tasks, thereby avoiding waste of resources caused by premature replacement or equipment damage caused by delayed maintenance, and improving the reliability of equipment operation and maintenance efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] 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.

[0038] Figure 1A schematic flow chart of a first embodiment of an industrial equipment maintenance system provided by the present invention.

[0039] Figure 2 A schematic diagram of an industrial equipment maintenance system provided by the present invention. DETAILED DESCRIPTION

[0040] 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.

[0041] Embodiment 1: Figure 1 , which is a flow chart of the first embodiment of the industrial equipment maintenance system of the present invention, provides the first embodiment of the industrial equipment maintenance system of the present invention.

[0042] In a first embodiment, the industrial equipment maintenance system includes:

[0043] Data acquisition module, used to collect lubricating oil status data of industrial equipment in real time through multiple types of sensors t , and the lubricating oil status data D t Transmitted to the preset gateway device; wherein the lubricating oil status data includes the lubricating oil viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t ;

[0044] The lubricating oil status data D t ={μ t ,C t ,O t}Transmit to the gateway device via Bluetooth or WiFi;

[0045] It should be noted that the lubricating oil status data D t It is the key data collected in real time by multiple types of sensors, including lubricating oil viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t , where the viscosity μ t It is used to reflect the fluidity of lubricating oil. Its abnormality may lead to insufficient lubrication or increase the load of equipment operation. Particle concentration C t Indicates the content of impurities in lubricating oil. Increased concentration will aggravate equipment wear; oxidation index O t It reflects the degree of chemical aging of the lubricant. Excessive oxidation will reduce the performance of the lubricant.

[0046] It is understandable that the lubricating oil status data D t ={μ t ,C t ,O t}'s real-time transmission is to ensure data integrity and timeliness. Sending data to the device gateway device via Bluetooth or WiFi can effectively reduce transmission delays. At the same time, Bluetooth is suitable for short-distance, low-power environments, while WiFi is suitable for transmission needs of larger data volumes or longer distances.

[0047] It should be understood that the real-time transmission and processing of lubricating oil status data is directly related to the response speed and accuracy of the maintenance system. For example, if the viscosity μ collected by the sensor is t If the pressure suddenly drops beyond the safety threshold, the system can generate maintenance instructions for load reduction or emergency shutdown through the analysis module, thereby avoiding serious damage to the equipment due to insufficient lubrication.

[0048] The data processing module is used to process the lubricating oil status data D using the preset gateway device. t Pre-processing to obtain lubricating oil status data D t2 The pre-processed lubricant status data D is transmitted through the narrowband Internet of Things NB-loT t2 Upload to the cloud server; the preprocessing includes data calibration and data compression;

[0049] The status judgment module is used to check the lubricating oil status data D on the cloud server. t2 Perform cleaning analysis and calculate lubricant deterioration index I t ;

[0050] The calculation of lubricant deterioration index includes: comprehensive analysis of lubricant viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t , the formula is:

[0051] I t =w 1 ·μ t +w 2 ·C t +w 3 ·O t

[0052] Among them, I t is the lubricant degradation index of the lubricant at time t, w 1 ,w 2 ,w 3 They represent the weight coefficients of lubricant oil viscosity, lubricant oil particle concentration and lubricant oil oxidation index respectively;

[0053] Through the preset lubricant degradation index threshold I threshold Determine the running status of lubricating oil S t , S t The values ​​include normal and need to be replaced;

[0054] It should be understood that the lubricant degradation index I t The dynamic calculation and status judgment of the system solves the problem that the lubricant status cannot be evaluated in real time in traditional fixed-cycle maintenance. This method can optimize the use efficiency of the lubricant and reduce the risk of equipment downtime caused by insufficient lubrication or contamination. t A decrease may indicate that the lubricant is not fluid enough to form an effective oil film; particle concentration C t An increase may mean that the lubricant is contaminated and needs to be cleaned or replaced; the oxidation index O t An increase indicates that the performance of the lubricant has deteriorated and maintenance measures need to be taken promptly.

[0055] Maintenance execution module, used to t Generate maintenance instruction C t , maintenance instruction formula:

[0056]

[0057] If S t = normal, then generate a continue running instruction; if S t = If replacement is required, a lubricant replacement instruction is generated;

[0058] Maintaining Directive C through Narrowband Internet of Things NB-IoT t Send it to the device and perform maintenance operations, including:

[0059] If C t = Replace the lubricant, the automatic lubrication system will be triggered to replace the lubricant or remind the maintenance personnel to replace the lubricant. After the lubricant is replaced, the lubricant viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t Initialize to the preset standard range;

[0060] It should be noted that the maintenance instructions C generated by the narrowband Internet of Things NB-loT technology t Sent to the device side to perform maintenance operations, NB-loT has the characteristics of low power consumption and wide coverage, and is particularly suitable for scenarios in industrial equipment that require reliable data transmission.

[0061] It can be understood that the role of the maintenance execution module is to convert the results of the status analysis into specific operation instructions to ensure that the equipment is always in the best operating state. t= Normal, the system maintains the current operating state, avoiding unnecessary maintenance and extending the service life of the lubricant; when S t =When replacement is required, maintenance instruction C is triggered t =Replace the lubricant and complete the lubricant replacement through the automatic lubrication system, or remind the maintenance personnel to perform the replacement operation; after completing the lubricant replacement operation, the system initializes the key parameters of the lubricant to the preset standard range. This automated maintenance process improves the maintenance efficiency of the system.

[0062] Maintenance optimization module, used to record and store lubricant historical status data history , the lubricating oil historical status data D history ={μ t ,C t ,O t ,I t}Stored in cloud server in timestamp sequence, based on historical status data D history Feedback adjustment of the weight coefficient w of the lubricant deterioration index 1 ,w 2 ,w 3 .

[0063] It should be noted that the maintenance optimization module analyzes the historical status data D history , dynamically adjust the weight w of the lubricant deterioration index 1 ,w 2 ,w 3 ,The weight adjustment mechanism optimizes the algorithm according to different ,operating environments and working conditions, ensuring that the system can flexibly adapt to the actual ,demands of the equipment.

[0064] For example, the historical status data of lubricating oil of industrial equipment is as follows:

[0065] Time point t 1 :μ t1 =8.5mPa,C t1 =500ppm,O t1 =20%;

[0066] Time point t 2 :μ t2 =7.8mPa,C t2 =800ppm,O t2 =25%;

[0067] Time point t 3 :μ t3 =7.2mPa,C t3 =1200ppm,O t3 =30%.

[0068] Deterioration index I calculated from historical datat and weight, w 1 =0.4,w 2 =0.4,w 3 =0.2; time point t 3 Deterioration index calculation, I t3 =0.4·7.2+0.4·1200+0.2·30=2.88+480+6=488.88, assuming threshold I thrcshold =450, the lubricant is judged to be replaced and the weight is adjusted dynamically. t Continuously increasing, it has a greater impact on degradation, and the system adjustment weight is w 1 =0.3, w 2 =0.5, w 3 =0.2 to pay more attention to the impact of contamination on lubricating oil.

[0069] It should be understood that the historical state data D of the lubricating oil history It is not only used to optimize the maintenance strategy of current equipment, but also to support the formulation of reference maintenance plans for similar equipment. For example, the change patterns of viscosity, particle concentration and oxidation index can be identified based on time series data to predict maintenance needs in advance; the lubricant replacement cycle of the equipment can be dynamically adjusted from a fixed cycle to state-based intelligent maintenance using data analysis results; when historical data analysis shows a significant deterioration trend, an alarm can be issued in advance to avoid equipment failures caused by operation in a deteriorated state.

[0070] In addition, the present invention also provides an industrial equipment maintenance device, please refer to Figure 2, an industrial equipment maintenance device includes: at least one processor; and a memory connected to the at least one processor in communication; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute an industrial equipment maintenance system in the above-mentioned embodiment 1. An industrial equipment maintenance device in the embodiment of the present invention may include but is not limited to mobile terminals such as mobile phones, laptop computers, digital broadcast receivers, PDAs (Personal Digital Assistants), PADs (Portable Application Descriptions), PMPs (Portable Media Players), vehicle-mounted terminals (such as vehicle-mounted navigation terminals), etc., and fixed terminals such as digital TVs, desktop computers, etc. An industrial equipment maintenance device is only an example and should not bring any limitation to the functions and scope of use of the embodiments of the present invention. An industrial equipment maintenance device may include a processing device 1001 (such as a central processing unit, a graphics processor, etc.), which can perform various appropriate actions and processes according to a program stored in a read-only memory (ROM) 1002 or a program loaded from a storage device 1003 to a random access memory (RAM) 1004. In RAM1004, various programs and data required for the operation of an industrial equipment maintenance device are also stored. The processing device 1001, ROM1002 and RAM1004 are connected to each other through a bus 1005. An input / output (I / O) interface 1006 is also connected to the bus. Generally, the following systems can be connected to the I / O interface 1006: an input device 1007 including, for example, a touch screen, a touchpad, a keyboard, a mouse, an image sensor, a microphone, an accelerometer, a gyroscope, etc.; an output device 1008 including, for example, a liquid crystal display (LCD: Liquid Crystal Display), a speaker, a vibrator, etc.; a storage device 1003 including, for example, a magnetic tape, a hard disk, etc.; and a communication device 1009. The communication device 1009 can allow an industrial equipment maintenance device to communicate wirelessly or wired with other devices to exchange data. Although an industrial equipment maintenance device with various systems is shown in the figure, it should be understood that it is not required to implement or have all the systems shown. More or fewer systems may be implemented or have alternatively.

[0071] The present invention also provides a computer program product, including a computer program, wherein when the computer program is executed by a processor, the steps of the industrial equipment maintenance system described above are implemented. The computer program product provided by the present invention can solve a technical problem of industrial equipment maintenance. Compared with the prior art, the beneficial effects of the computer program product provided by the present invention are the same as the beneficial effects of the industrial equipment maintenance system provided by the above embodiment, which will not be described in detail here.

[0072] In particular, according to the embodiments disclosed in the present invention, the process described above with reference to the flowchart can be implemented as a computer software program. For example, the embodiments disclosed in the present invention include a computer program product, which includes a computer program carried on a computer-readable medium. In such an embodiment, the computer program can be downloaded and installed from a network through a communication device, or installed from a storage device 1003, or installed from a ROM 1002. When the computer program is executed by the processing device 1001, the above-mentioned functions defined in the system of the embodiments disclosed in the present invention are executed.

[0073] It should be understood that the various parts disclosed in the present invention can be implemented by hardware, software, firmware or a combination thereof. In the description of the above embodiments, specific features, structures, materials or characteristics can be combined in any one or more embodiments or examples in a suitable manner.

[0074] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. An industrial equipment maintenance system, characterized in that the system include: Data acquisition module, used to collect lubricating oil status data of industrial equipment in real time through multiple types of sensors t , and the lubricating oil status data D t Transmitted to the preset gateway device; wherein the lubricating oil status data includes the lubricating oil viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t ; The lubricating oil status data D t ={μ t ,C t ,O t }Transmit to the gateway device via Bluetooth or WiFi; The data processing module is used to process the lubricating oil status data D using the preset gateway device. t Pre-processing to obtain lubricating oil status data D t2 The pre-processed lubricant status data D is transmitted through the narrowband Internet of Things NB-loT t2 Upload to the cloud server; the preprocessing includes data calibration and data compression; The status judgment module is used to check the lubricating oil status data D on the cloud server. t2 Perform cleaning analysis and calculate lubricant deterioration index I t ; The calculation of lubricant deterioration index includes: comprehensive analysis of lubricant viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t , the formula is: I t =w1·μ t +w2·C t +w3·O t Among them, I t is the lubricant degradation index of the lubricant at time t, w1, w2, w3 represent the weight coefficients of lubricant viscosity, lubricant particle concentration and lubricant oxidation index respectively; Through the preset lubricant degradation index threshold I threshold Determine the running status of lubricating oil S t , S t The values ​​include normal and need to be replaced; Maintenance execution module, used to t Generate maintenance instruction C t , maintenance instruction formula: If S t = normal, then generate a continue running instruction; if S t = If replacement is required, a lubricant replacement instruction is generated; Maintaining Directive C through Narrowband Internet of Things NB-IoT t Send it to the device and perform maintenance operations, including: If C t = Replace the lubricant, the automatic lubrication system will be triggered to replace the lubricant or remind the maintenance personnel to replace the lubricant. After the lubricant is replaced, the lubricant viscosity μ t , Lubricating oil particle concentration C t and lubricating oil oxidation index O t Initialize to the preset standard range; Maintenance optimization module, used to record and store lubricant historical status data history , the lubricating oil historical status data D history ={μ t ,C t ,O t ,I t }Stored in cloud server in timestamp sequence, based on historical status data D history Feedback adjusts the weight coefficients w1, w2, w3 of the lubricant degradation index.

2. An industrial equipment maintenance system as claimed in claim 1, characterized in that: In the data acquisition module, the lubricating oil status data includes: Lubricating oil viscosity μ t , used to represent the dynamic fluidity of the lubricating oil at time t, in Pascals per second, collected by an online viscosity sensor; Lubricating oil particle concentration C t , used to indicate the concentration of foreign particles in lubricating oil, in parts per million, collected by particle sensors; Lubricating oil oxidation index O t , used to indicate the degree of oxidation of lubricating oil in percentage, collected by spectral analysis sensor.

3. An industrial equipment maintenance system as claimed in claim 1, characterized in that: In the data collection module, the collection time interval Δt is set. The collection time interval Δt is dynamically adjusted according to the equipment operation intensity. The unit is hours and the range is 1h≤Δt≤24h.

4. An industrial equipment maintenance system as claimed in claim 1, characterized in that: In the data processing module, data calibration processing includes: Lubricating oil status data D t Perform linear calibration, the formula is: in, is the lubricating oil state data after linear calibration, k is the calibration coefficient of the lubricating oil state data, and b is the bias term of the lubricating oil state data.

5. An industrial equipment maintenance system as claimed in claim 4, characterized in that: In the data processing module, data compression processing includes: Using differential compression algorithm to process lubricating oil condition data after linear calibration The formula is: Among them, D t2 is the lubricating oil status data after pretreatment, It is the difference between the lubricating oil state data after linear calibration at the current time t and the previous time t-1.

6. An industrial equipment maintenance system as claimed in claim 1, characterized in that: In the state judgment module, cleaning analysis includes using boundary detection algorithm to remove abnormal values. Then remove D t2 , where D min and D max They are respectively the upper and lower thresholds for safe operation of lubricating oil status data.

7. An industrial equipment maintenance system as claimed in claim 1, characterized in that: In the status judgment module, the judgment formula for the running status of the lubricating oil is: Among them, S t It is the lubricating oil running state.

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