Intelligent vibration detector

Abstract

The invention designs an intelligent vibration detector. Based on an intelligent vibration detector device software and hardware module, the intelligent vibration detector device software and hardware module comprises a six-dimensional vibration detection module, a main control module, a relay module, a signal processing module and a communication module. According to the control method, firstly, the six-dimensional vibration detection module establishes a space rectangular coordinate system, collects current motion data and sends the current motion data to the main control module through the communication module, and the main control module calculates the current vibration speed and vibration attitude data and is used for analyzing and processing the collected signals and sending the processed signals to the control module. The main control module automatically detects whether the functions of the product work normally or not in real time and gives an alarm in time, and when an upper computer receives data transmitted by the main control module, the upper computer effectively analyzes data signals through time domain analysis, frequency domain analysis and time-frequency domain analysis by means of the time domain analysis method, the frequency domain analysis method and the time-frequency domain analysis method. The vibration detection device can monitor and analyze vibration signals in real time, is widely applied to the fields of mechanical equipment, industrial monitoring and the like, and is a multi-dimensional and intelligent vibration detection device capable of generating comprehensive signals in real time.

Description

Technical Field

[0001] The present invention relates to vibration detection equipment in the field of measurement technology, specifically to an intelligent vibration detection device, which can monitor and analyze vibration signals in real time and is widely used in mechanical equipment, industrial monitoring and other fields. Background Art

[0002] With the continuous advancement of industrialization, mechanical equipment plays a vital role in all walks of life. The normal operation of equipment directly affects production efficiency and economic benefits. However, during the long-term operation of mechanical equipment, failures may occur due to various factors (such as wear, vibration, temperature changes, etc.), especially abnormal vibration is an early sign of mechanical equipment failure. Traditional equipment fault diagnosis methods rely on manual inspections and regular maintenance, but these methods not only have problems such as delayed response and low efficiency, but also have difficulty in detecting potential faults in a timely manner, which can easily lead to equipment downtime and production interruptions, thereby increasing maintenance costs and production losses. With the development of industrial automation, the accuracy and real-time requirements of vibration detection are getting higher and higher. Therefore, there is an urgent need for a vibration detection device that is multi-dimensional, intelligent, and generates comprehensive signals in real time. Summary of the invention

[0003] In order to adapt to the rapid development trend of industrial automation, the present invention designs a vibration monitoring device that is multi-dimensional, intelligent, and can generate comprehensive signals in real time. The device not only has the ability of multi-band monitoring, but also can collect and process vibration signals in real time to meet the high requirements of modern industrial equipment for precise monitoring during operation. Its core feature is that it can support multi-band monitoring and analyze vibration signals in different frequency bands, so as to effectively identify the operating status of the equipment and predict possible failures or abnormalities in advance. The vibration monitoring device also integrates real-time data processing and alarm functions, which can monitor vibration changes in real time during equipment operation, and promptly feedback potential risks to ensure safe and stable operation of the equipment. The device improves the accuracy and response speed of vibration detection through the combination of high-precision sensors and intelligent algorithms, greatly optimizes the operation and maintenance efficiency of the industrial automation system, and provides reliable data support for equipment fault diagnosis and preventive maintenance.

[0004] The present invention adopts the following technical solution, based on an intelligent vibration detection device, the software and hardware modules of the device include: a six-dimensional vibration detection module, a main control module, a relay module, a signal processing module and a communication module, wherein:

[0005] The six-dimensional vibration detection module is used to establish a spatial rectangular coordinate system, collect current vibration data, and send it to the main control module through the communication module;

[0006] The main control module is used to calculate the current vibration speed and vibration posture of the object based on the current vibration data, and the current vibration posture includes linear vibration and rotational vibration to determine the vibration direction;

[0007] The relay module is used to analyze and process the collected signals, conduct real-time self-checks to see if the functions of the product itself are working properly, and promptly issue an alarm;

[0008] The signal processing module is used to analyze and process the collected signals. When the host computer receives the data from the main control module, it performs time domain analysis, frequency domain analysis and time-frequency domain analysis on the data signal. The time domain analysis includes the extraction of velocity and acceleration data features, the frequency domain analysis includes fast Fourier transform FFT, and the time-frequency domain analysis includes empirical mode decomposition EMD, variational mode decomposition VMD and orthogonal mode decomposition OMD to effectively analyze the data signal.

[0009] The communication module is used to realize data transmission between modules, and includes an integrated circuit bus, including an IIC bus and a CANOPEN bus.

[0010] Furthermore, a detection process of an intelligent vibration detector includes the following steps:

[0011] Step 1) The six-dimensional vibration detection module establishes a spatial rectangular coordinate system, collects vibration data of the current object being measured, and sends it to the main control module through the communication module;

[0012] Step 2) The main control module calculates the current object vibration speed and vibration posture based on the current object vibration data, and sends them to the signal processing module through the communication module. The current vibration posture includes linear vibration and rotational vibration to determine the vibration direction;

[0013] Step 3) The relay module responds according to whether the value of the object vibration data exceeds the alarm threshold according to the main control module, so as to detect whether the state of the object is abnormal in real time;

[0014] Step 4) When the signal processing module determines that the value of the object vibration data does not exceed the alarm threshold according to the main control module, the data signal is subjected to time domain analysis, frequency domain analysis and time-frequency domain analysis. The time domain analysis includes the extraction of velocity and acceleration data features, the frequency domain analysis includes fast Fourier transform FFT, and the time-frequency domain analysis includes empirical mode decomposition EMD, variational mode decomposition VMD and orthogonal mode decomposition OMD, and the waveform is reflected in the host computer.

[0015] The beneficial effects achieved by the invention: The present invention is an intelligent vibration detection device, which can monitor and analyze vibration signals in real time, and can promptly alarm when the vibration of an object exceeds its vibration range threshold. The use of time domain analysis, frequency domain analysis, and time-frequency domain analysis when analyzing data greatly improves the accuracy of the data, and is widely used in mechanical equipment, industrial monitoring and other fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a general structural block diagram of an embodiment of the present invention;

[0017] Figure 2 is a flow chart of a method for calculating vibration velocity according to an embodiment of the present invention;

[0018] Figure 3 It is a flow chart of a control method according to an embodiment of the present invention. DETAILED DESCRIPTION

[0019] The device can be applied in various industrial equipment. By real-time monitoring of vibration signals, equipment failures can be discovered in time, thereby reducing maintenance costs and improving the safety and reliability of equipment. The technical solution of the present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0020] Figure 1 It is a block diagram of the structure of intelligent vibration detection equipment. Based on intelligent vibration detection equipment, the software and hardware modules of the device include: six-dimensional vibration detection module, main control module, relay module, signal processing module, communication module,

[0021] Furthermore, the six-dimensional vibration detection module is used to establish an accurate rectangular coordinate system in three-dimensional space, and comprehensively monitor the vibration state of the device through the coordinate system; the module collects the vibration data of the device in real time through sensors, including key parameters such as acceleration and angular velocity, so as to comprehensively reflect the posture changes of the device; after the collected vibration data is initially processed, it is quickly transmitted to the main control module through the communication module to ensure the timeliness and accuracy of the data;

[0022] Furthermore, the main control module (MCU) is used for real-time vibration data calculation and acquisition of the vibration speed and vibration posture information of the current device; the module accurately calculates the vibration state of the device through real-time analysis of the vibration signal, and converts it into a corresponding waveform diagram for visualization and further analysis; specifically, the vibration posture of the current vibration mainly includes two forms: linear vibration and rotational vibration; linear vibration is used to describe the reciprocating vibration of the device in a specific direction, and its vibration direction can be automatically identified by a precise algorithm; rotational vibration represents the rotational vibration of the device around a certain axis, and the main control module can monitor and analyze the changes in the rotation mode in real time;

[0023] Furthermore, the relay module is used to analyze and process the collected signals. If the detected object vibration data exceeds the set threshold, the relay module will give an alarm in time; if the detected object vibration data is within the normally set threshold range, no alarm will be given; the module can self-check in real time whether its own product functions are working normally and give an alarm in time;

[0024] Furthermore, the signal processing module is used to analyze and process the collected signals, and perform time domain analysis, frequency domain analysis and time-frequency domain analysis on the data signals. The time domain analysis includes extraction of velocity and acceleration data features, the frequency domain analysis includes fast Fourier transform FFT, and the time-frequency domain analysis includes empirical mode decomposition EMD, variational mode decomposition VMD and orthogonal mode decomposition OMD, so as to effectively analyze the data signals.

[0025] Furthermore, the communication module is used to realize data transmission between modules, including an IIC bus and a CANOPEN bus. The six-dimensional vibration detection module and the main control module communicate data through the integrated circuit bus IIC communication method, and the main control module and the signal processing module of the host computer realize data transmission through the CANOPEN bus.

[0026] In this embodiment, a 5V stabilized lithium battery is used to power the six-dimensional vibration detection module. The 5V stabilized lithium battery powers the main control module and the communication module through the power conversion chip LM1117-3.3V stabilizer chip.

[0027] As a preferred embodiment, the main control module adopts STM32F407VET6.

[0028] As a preferred embodiment, the six-dimensional vibration detection module includes a three-axis acceleration sensor and a three-axis gyroscope, and detects the vibration state of the object being measured by detecting six-axis data.

[0029] As a preferred embodiment, the six-dimensional vibration detection module adopts the MPU6050 six-axis vibration sensor.

[0030] As a preferred embodiment, the communication module is connected to the host computer using a CAN-USB adapter.

[0031] Furthermore, based on an intelligent vibration sensor, the specific steps are as follows:

[0032] Step 1) The six-dimensional vibration detection module establishes a spatial rectangular coordinate system, collects current vibration data, and sends it to the main control module through the communication module; in this embodiment, the landing point of the object to be measured is the coordinate origin of the spatial rectangular coordinate system;

[0033] Step 2) The main control module calculates the current vibration speed and vibration posture data based on the current vibration data, and sends them to the signal processing module through the communication module. The current vibration posture includes linear vibration and rotational vibration to determine the vibration direction;

[0034] Step 3) The relay module responds according to whether the value of the object vibration data exceeds the alarm threshold according to the main control module, so as to detect whether the state of the object is abnormal in real time;

[0035] Step 4) When the signal processing module determines that the value of the object vibration data does not exceed the alarm threshold according to the main control module, the data signal is subjected to time domain analysis, frequency domain analysis and time-frequency domain analysis. The time domain analysis includes the extraction of velocity and acceleration data features, the frequency domain analysis includes fast Fourier transform FFT, and the time-frequency domain analysis includes empirical mode decomposition EMD, variational mode decomposition VMD and orthogonal mode decomposition OMD to effectively analyze the data signal.

[0036] Figure 2 This is a flow chart of a method for calculating vibration speed. The method for calculating the current vibration speed is specifically as follows:

[0037] When the object vibrates, acceleration data is collected by the acceleration sensor in the vibration detection module, and the main control module calculates the vibration speed along the X, Y, and Z axes according to the relationship between acceleration and speed; if the object vibrates linearly along the X, Y, and Z main axes, the speed that is not 0 is the combined vibration speed; if the object vibrates linearly deviating from the X, Y, and Z main axes, the combined vibration speed is accurately calculated according to the vibration speed along the X, Y, and Z axes through the Pythagorean theorem; the combined vibration speed is the current vibration speed.

[0038] Furthermore, the method for calculating the current vibration posture is specifically as follows:

[0039] s1) Determine the vibration direction: Based on the spatial rectangular coordinate system established in step 1), in this embodiment, the direction facing the object is the positive direction of the X axis, the left side is the positive direction of the Y axis, and the top is the positive direction of the Z axis; the gyroscope in the vibration detection module takes the clockwise rotation direction around the positive direction of the X, Y, and Z axes as the positive direction, and determines the vibration direction of the object by detecting data in six directions;

[0040] Furthermore, the method for determining the vibration direction is determined by judging the signs of the acceleration and angular velocity data obtained by the vibration detection module. If the sign of the acceleration data is positive, it is along the positive direction of the coordinate axis, and if the sign of the acceleration data is negative, it is along the reverse direction of the coordinate axis. If the sign of the angular velocity data is positive, it rotates clockwise around the positive direction of the coordinate axis, and if the sign of the angular velocity data is negative, it rotates counterclockwise around the positive direction of the coordinate axis.

[0041] s2) Determine the current vibration posture: The main control module performs posture fusion algorithm calculation on the acceleration data detected by the acceleration sensor in the vibration detection module and the vibration angle data detected by the gyroscope to obtain the current vibration posture of the object. The current vibration posture includes linear vibration and rotational vibration to determine the vibration direction. It should be noted that the use of posture fusion algorithm to calculate the vibration posture is a prior art.

[0042] Furthermore, the linear vibration for determining the vibration direction of the object includes: linear vibration along the X, Y, and Z axis directions and linear vibration deviating from the X, Y, and Z axis directions; the linear vibration along the X, Y, and Z axis directions includes forward or backward along the X axis direction, left or right along the Y axis direction, and upward or downward along the Z axis direction, and the linear vibration deviating from the X, Y, and Z axis directions includes: left front (between the positive direction of the Y axis and the positive direction of the X axis), left rear (between the positive direction of the Y axis and the negative direction of the X axis), right front (between the negative direction of the Y axis and the positive direction of the X axis), right rear (between the positive direction of the Y axis and the negative direction of the X axis), The upper left and lower left, the upper right and lower right (between the positive and negative directions of the Y axis and the positive direction of the Z axis), the upper front and lower front, the upper back and lower back (between the positive and negative directions of the X axis and the positive direction of the Z axis), the upper left front, the lower left front (between the positive direction of the Y axis, the positive direction of the X axis and the positive direction of the Z axis), the upper left back, the lower left back (between the positive direction of the Y axis, the negative direction of the X axis and the positive direction of the Z axis), the upper right front, the lower right front (between the negative direction of the Y axis, the positive direction of the X axis and the positive direction of the Z axis), the upper right back, the lower right back (between the negative direction of the Y axis, the negative direction of the X axis and the positive direction of the Z axis).

[0043] Furthermore, in the six-dimensional vibration detection module, an acceleration sensor is used to detect and obtain acceleration data. In order to improve data measurement accuracy, the collected original acceleration signal is subjected to time domain analysis, frequency domain analysis, and time-frequency domain analysis.

[0044] The method for analyzing vibration signals is specifically as follows: time domain analysis includes extraction of velocity and acceleration data features, frequency domain analysis includes fast Fourier transform FFT, time-frequency domain analysis includes empirical mode decomposition EMD, variational mode decomposition VMD and orthogonal mode decomposition OMD, so as to effectively analyze the data signal.

[0045] Figure 3 The present invention is a flow chart of a control method for an intelligent vibration detection device. The step 1) also includes taking the position where the object is placed as the coordinate origin of the spatial rectangular coordinate system, taking the coordinate origin as the center of the circle, and setting a circle with a preset radius as the vibration range. If the vibration range is exceeded, the control is terminated to achieve a relay alarm effect; if the vibration range is within the vibration range, the process proceeds to step 2). The system is initialized before step 1).

[0046] in conclusion

[0047] The intelligent vibration detection device of the present invention has significant advantages in terms of accuracy, functionality and integration, and can effectively meet the high standards of modern industry for vibration monitoring systems. First, the device uses advanced sensing technology and sophisticated data processing algorithms to ensure high-precision vibration detection and real-time monitoring, and can accurately capture tiny vibration changes and promptly identify potential equipment failure risks. Secondly, the device has multiple functions. In addition to conventional vibration monitoring, it can also realize fault diagnosis, data storage, remote monitoring, alarm and other intelligent operations, greatly improving the operating efficiency and safety of industrial equipment.

[0048] The design of this device takes into account the need for easy integration with existing industrial automation systems. It has good compatibility and scalability, and can be seamlessly connected to different types of equipment and control platforms, making it convenient for users to perform unified management and operation. With its efficient performance, flexible functional configuration and easy integration, this intelligent vibration detection device has shown a wide range of application prospects, especially for equipment status monitoring and preventive maintenance in modern manufacturing, energy, transportation and other industries, providing strong technical support for enterprises to reduce failure risks and improve production efficiency.

Claims

1. An intelligent vibration detector, characterized in that The vibration data of the object is detected by the micro-electromechanical system (MEMS) acceleration sensor MPU6050, and the data signal is analyzed in the time domain, frequency domain and time-frequency domain inside the device. The time domain analysis includes the extraction of velocity and acceleration data features, the frequency domain analysis includes fast Fourier transform FFT, and the time-frequency domain analysis includes empirical mode decomposition EMD, variational mode decomposition VMD and orthogonal mode decomposition OMD. The hardware and software modules of the device include: six-dimensional vibration detection module, main control module, relay module, signal processing module and communication module. The six-dimensional vibration detection module adopts the MPU6050 six-axis acceleration sensor and temperature sensor to establish a spatial rectangular coordinate system, collect current vibration data and temperature data, and send them to the main control module through the communication module; The main control module adopts the STM32F407VET6 minimum system board, which is used to calculate the current vibration speed and vibration posture of the current vibration data, and the current vibration posture includes linear vibration and rotational vibration to determine the vibration direction; The relay module is used to analyze the collected signals, conduct real-time self-checks to see if the functions of the product are working properly, and promptly issue an alarm; The signal processing module is used to analyze the collected signals. When the host computer receives the data from the main control module, it uses time domain analysis, frequency domain analysis and time-frequency domain analysis. The time domain analysis includes the extraction of velocity and acceleration data features, the frequency domain analysis includes fast Fourier transform FFT, and the time-frequency domain analysis includes empirical mode decomposition EMD, variational mode decomposition VMD and orthogonal mode decomposition OMD. These methods are used to effectively analyze the data signal. The communication module is used to realize data transmission between modules, and includes an integrated circuit bus, including an IIC bus and a CANOPEN bus.

2. An intelligent vibration detector according to claim 1, characterized in that: The method for calculating the current vibration speed is specifically as follows: when the object under test is vibrating linearly, acceleration data is collected by the acceleration sensor in the six-dimensional vibration detection module, and the main control module calculates the vibration speed along the X, Y, and Z axes according to the relationship between acceleration and speed; If the object being measured vibrates linearly along the X, Y, and Z principal axes, the speed that is not 0 is the combined vibration speed; If the object being measured performs linear vibration that deviates from the directions of the X, Y, and Z principal axes, the combined vibration velocity is accurately calculated using the Pythagorean theorem based on the vibration velocities along the X, Y, and Z axes; the combined vibration velocity is the current vibration velocity.

3. The intelligent vibration detector according to claim 1, characterized in that: The detection process of the intelligent vibration detector includes the following steps: Step 1) The six-dimensional vibration detection module establishes a spatial rectangular coordinate system, collects vibration data of the current object being measured, and sends it to the main control module through the communication module; Step 2) The main control module calculates the current object vibration speed and vibration posture based on the current object vibration data, and sends them to the signal processing module through the communication module. The current vibration posture includes linear vibration and rotational vibration to determine the vibration direction; Step 3) The relay module responds according to whether the value of the object vibration data exceeds the alarm threshold according to the main control module, so as to detect whether the state of the object is abnormal in real time; Step 4) When the signal processing module determines that the value of the object vibration data does not exceed the alarm threshold according to the main control module, the data is analyzed in the time domain, frequency domain and time-frequency domain, and the waveform is reflected in the host computer.

4. According to the intelligent vibration detector according to claim 1 or claim 3, the detection process of the intelligent vibration detector is characterized in that: The method for calculating the current vibration speed is specifically as follows: when the object under test is vibrating linearly, acceleration data is collected by the acceleration sensor in the six-dimensional vibration detection module, and the main control module calculates the vibration speed along the X, Y, and Z axes according to the relationship between acceleration and speed; If the object being measured vibrates linearly along the X, Y, and Z principal axes, the speed that is not 0 is the combined vibration speed; If the object being measured performs linear vibration that deviates from the directions of the X, Y, and Z principal axes, the combined vibration velocity is accurately calculated using the Pythagorean theorem based on the vibration velocities along the X, Y, and Z axes; the combined vibration velocity is the current vibration velocity.

5. According to the intelligent vibration detector according to claim 1 or claim 3, the detection process of the intelligent vibration detector is characterized in that: The method for calculating the current vibration posture is specifically as follows: s1) Determine the vibration direction: Based on the spatial rectangular coordinate system established in step 1), the gyroscope in the six-dimensional vibration detection module takes the clockwise rotation direction around the positive direction of the X, Y, and Z axes as the positive direction, and determines the vibration direction of the object by detecting data in the six directions; s2) Determine the current vibration posture: The main control module performs posture fusion algorithm calculation on the acceleration data detected by the acceleration sensor in the six-dimensional vibration detection module and the vibration angle data detected by the gyroscope to obtain the current vibration posture of the object.

6. According to the intelligent vibration detector according to claim 1 or claim 3, the detection process of the intelligent vibration detector is characterized in that: The main control module contains a system fault relay that can respond when power failure, overload, processor hang and sensor damage occur.

7. According to claim 1 or claim 3, the intelligent vibration detector, the detection process of the intelligent vibration detector is characterized in that: The step 1) also includes setting a vibration threshold of the object to be measured in the main control module. If the vibration threshold exceeds the vibration range, the alarm relay responds; if the vibration threshold is within the vibration range, the process proceeds to step 2).

8. According to the intelligent vibration detector according to claim 1 or claim 3, the detection process of the intelligent vibration detector is characterized in that: The orthogonal modal decomposition (OMD) in time-frequency domain analysis has the orthogonality and uniqueness of global modal decomposition. The precise definition of the modes ensures that all modes have clear center positions and widths in the frequency domain, and there is no overlap between modes.

9. The intelligent vibration detector according to claim 1, characterized in that: The six-dimensional vibration detection module and the main control module communicate with each other via the IIC bus, and the main control module of the intelligent vibration detector and the host computer communicate with each other via the CANOPEN bus.

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