A post-use detection and early warning system and method for construction equipment

Abstract

The present invention relates to the field of device detection technology, and discloses a post-use detection and early warning system and method for construction equipment. The system comprises: a sensor assembly, including a voltage sensor, a current sensor, a vibration sensor, and a temperature sensor; a control module, configured to collect generator power information and operating condition information, obtain an electrical evaluation value of the generator based on the power information, obtain a mechanical evaluation value of the generator based on the operating condition information, and comprehensively evaluate the generator performance based on the electrical and mechanical evaluation values ​​and issue an early warning; wherein the control module comprises a collection unit, a processing unit, and an early warning unit. By integrating real-time monitoring of power information and operating condition information, the present invention can achieve comprehensive monitoring and effectively improve the performance evaluation and fault early warning capabilities of the generator after use.

Description

Technical Field

[0001] The present invention relates to the field of device detection technology, and in particular to a post-use detection and early warning system and method for a construction device. Background Art

[0002] With the continuous development of modern construction equipment, especially generator equipment in the power industry, ensuring the stability and safety of equipment after long-term operation has become a key issue in project operation and maintenance. As the core equipment for power production and transmission, the operating status of generators directly affects the reliability and safety of power supply.

[0003] Traditional generator monitoring methods typically rely on manual inspections and regular maintenance, which have certain limitations, such as the inability to monitor the operating status of the equipment in real time and the subjectivity of manual judgment. Therefore, the development of a system that can monitor the operating status of generators in real time, detect faults in a timely manner, and issue warnings has become an urgent need for modern equipment management. In addition, in existing technologies, fault diagnosis and warning for generators mostly use a single monitoring method, usually only performing a single test. However, a single monitoring method cannot fully assess the operating status of the generator, especially when abnormal power fluctuations and mechanical failures coexist, making it impossible to accurately and comprehensively diagnose equipment problems.

[0004] Therefore, it is necessary to provide a post-use detection and early warning system and method for a construction device to solve the problem in the prior art that a single monitoring means cannot comprehensively and efficiently diagnose generator faults. Summary of the Invention

[0005] In view of this, the present invention proposes a post-use detection and early warning system and method for a construction device, aiming to solve the problem in the prior art that a single monitoring means cannot comprehensively and efficiently diagnose generator faults.

[0006] In one aspect, the present invention provides a post-use detection and warning system for a construction device, comprising:

[0007] A sensor assembly, comprising a voltage sensor, a current sensor, a vibration sensor and a temperature sensor, wherein the voltage sensor and the current sensor are arranged at the output end of the generator, and the vibration sensor and the temperature sensor are arranged on the bearing seat;

[0008] a control module configured to collect power information and operating condition information of the generator, obtain an electrical evaluation value of the generator based on the power information, obtain a mechanical evaluation value of the generator based on the operating condition information, and comprehensively evaluate the performance of the generator based on the electrical and mechanical evaluation values ​​and issue an early warning; wherein the control module includes a collection unit, a processing unit, and an early warning unit;

[0009] The acquisition unit is used to acquire power information and operating condition information of the generator, wherein the power information includes output voltage and output current, and the operating condition information includes bearing vibration information and bearing temperature information;

[0010] The processing unit is configured to calculate the electrical evaluation value based on the fluctuation value of the output voltage and the fluctuation value of the output current, determine whether to adjust the electrical evaluation value based on the duration of the voltage fluctuation, and if it is determined to be adjusted, adjust the electrical evaluation value based on the duration of the voltage fluctuation and the duration of the voltage fluctuation interval to obtain a final electrical evaluation value;

[0011] The processing unit is further configured to calculate the mechanical evaluation value based on the bearing vibration information, determine whether to adjust the mechanical evaluation value based on the bearing temperature information, and if so, adjust the mechanical evaluation value based on the temperature information to obtain a final mechanical evaluation value.

[0012] The early warning unit is used to obtain a total detection value by weighted summing the final value of the electrical evaluation and the initial value of the mechanical evaluation, and to issue an early warning based on the total detection value.

[0013] Furthermore, when the processing unit is used to calculate the electrical property evaluation value according to the fluctuation value of the output voltage and the fluctuation value of the output current, it includes:

[0014] Constructing a voltage fluctuation value sequence and a current fluctuation value sequence within a unit time, and arranging the values ​​in the voltage fluctuation value sequence and the current fluctuation value sequence in descending order respectively;

[0015] The maximum voltage fluctuation value in the voltage fluctuation value sequence and the maximum current fluctuation value in the current fluctuation value sequence are selected, and the electrical property evaluation value is calculated according to the maximum voltage fluctuation value, the number of voltage fluctuations, the maximum current fluctuation value, and the number of current fluctuations:

[0016]

[0017] In the above formula, Sd represents the electrical evaluation value, a represents the voltage fluctuation weight coefficient, NV represents the number of voltage fluctuations, Vk represents the kth voltage fluctuation value, b represents the current fluctuation weight coefficient, NI represents the number of current fluctuations, Vj represents the jth current fluctuation value, and a+b=1.

[0018] Furthermore, when the processing unit is used to determine whether to adjust the electrical property evaluation value according to the duration of the voltage fluctuation, it includes:

[0019] Setting a maximum voltage fluctuation duration per unit time, collecting a total voltage fluctuation duration per unit time, and determining that the electrical evaluation value needs to be adjusted if the total voltage fluctuation duration is greater than the maximum voltage fluctuation duration;

[0020] If the total duration of the voltage fluctuation is less than or equal to the maximum duration of the voltage fluctuation, it is determined that the electrical property evaluation value does not need to be adjusted.

[0021] Furthermore, if the processing unit is determined to be an adjustment, the electrical evaluation value is adjusted according to the voltage fluctuation duration and the voltage fluctuation interval duration to obtain a final electrical evaluation value, including:

[0022] Constructing a voltage fluctuation interval duration sequence Tx={t1, t2, ..., tn} within a unit time, calculating an impact factor based on each interval duration value in the interval duration sequence and the total duration of the voltage fluctuation, and adjusting the electrical property evaluation value based on the impact factor;

[0023] The impact factor is calculated by the following formula:

[0024]

[0025] In the above formula, F represents the impact factor, n represents the number of values ​​in the interval duration sequence, ti represents the i-th interval duration, T represents the total duration of voltage fluctuation, and wi represents the weight of each interval duration ti.

[0026] Furthermore, if the processing unit is used to determine that adjustment is required, the processing unit adjusts the electrical evaluation value according to the voltage fluctuation duration and the voltage fluctuation interval duration to obtain the final electrical evaluation value, further comprising:

[0027] Set the minimum and maximum impact factors;

[0028] If the impact factor is less than the minimum impact factor, adjusting the electrical property evaluation value by a first adjustment coefficient;

[0029] If the impact factor is greater than or equal to the minimum impact factor and less than or equal to the maximum impact factor, the electrical property evaluation value is adjusted by a second adjustment coefficient;

[0030] If the impact factor is greater than the maximum impact factor, adjusting the electrical property evaluation value by a third adjustment coefficient;

[0031] The first adjustment coefficient is smaller than the second adjustment coefficient, and the second adjustment coefficient is smaller than the third adjustment coefficient.

[0032] Furthermore, the processing unit is further configured to calculate the mechanical evaluation value according to the bearing vibration information, including:

[0033] A standard vibration value is preset, a vibration waveform output by a vibration sensor within a unit time is collected, an average vibration value is calculated, and the mechanical evaluation value is calculated based on the average vibration value and the peak vibration value:

[0034] Sj=k*Aavg*e Af / A0 ;

[0035] In the above formula, Sj represents the mechanical evaluation value, k represents the adjustment coefficient, Aavg represents the average vibration value, Af represents the peak vibration value, and A0 represents the standard vibration value.

[0036] Furthermore, the processing unit is further configured to determine whether to adjust the mechanical evaluation value according to the bearing temperature information, including:

[0037] Preset a maximum bearing temperature, and if the bearing temperature is less than or equal to the maximum bearing temperature, determine that there is no need to adjust the mechanical evaluation value;

[0038] If the bearing temperature is greater than the maximum bearing temperature, it is determined that the mechanical evaluation value needs to be adjusted.

[0039] Furthermore, the processing unit is further configured to adjust the mechanical evaluation value according to the temperature information if it is determined to be an adjustment, and to obtain a final mechanical evaluation value, including:

[0040] Setting a first temperature and a second temperature, wherein the first temperature is lower than the second temperature;

[0041] If the bearing temperature is lower than the first temperature, adjusting the mechanical evaluation value by a first adjustment coefficient;

[0042] If the bearing temperature is greater than or equal to the first temperature and less than or equal to the second temperature, adjusting the mechanical evaluation value by a second adjustment coefficient;

[0043] If the bearing temperature is greater than the second temperature, adjusting the mechanical evaluation value by a third adjustment coefficient;

[0044] The first adjustment coefficient is greater than the second adjustment coefficient, and the second adjustment coefficient is greater than the third adjustment coefficient.

[0045] Furthermore, the early warning unit is configured to obtain a total detection value by weighted summing the final value of the electrical evaluation and the initial value of the mechanical evaluation. When issuing an early warning based on the total detection value, the early warning includes:

[0046] Sz=a*Sd1+γ*Sj1;

[0047] In the above formula, Sz represents the total test value, α represents the weight coefficient of the final value of the electrical evaluation, Sd1 represents the final value of the electrical evaluation, β represents the weight coefficient of the final value of the mechanical evaluation, and Sj1 represents the final value of the mechanical evaluation;

[0048] Set a first total value and a second total value, and the first total value is smaller than the second total value;

[0049] If the total detection value is less than the first total value, a first-level warning is issued;

[0050] If the total detection value is greater than or equal to the first total value and less than or equal to the second total value, a second-level warning is issued;

[0051] If the total detection value is greater than the second total value, a third-level warning is issued;

[0052] Among them, the warning levels from low to high are level one warning, level two warning and level three warning.

[0053] Compared with existing technologies, the present invention offers the following advantages: by integrating real-time monitoring of power and mechanical operating conditions, the system effectively enhances post-operation performance evaluation and fault warning capabilities. Voltage and current sensors monitor power fluctuations at the generator output, while vibration and temperature sensors track the operating status of the bearing housing in real time, providing critical mechanical operating data. By combining electrical and mechanical evaluation values, the system comprehensively assesses the generator's operating status and conducts a comprehensive analysis of its electrical and mechanical performance. This dual monitoring mechanism promptly detects power fluctuations or mechanical anomalies, preventing potential failures and ensuring safe equipment operation and extending its service life. In particular, when voltage fluctuations or mechanical vibrations exceed predetermined thresholds, the system intelligently adjusts the evaluation values ​​and issues warnings, prompting operators to take timely action, thereby improving safety and efficiency during operation. Ultimately, this comprehensive evaluation-based warning function provides a scientific basis for equipment maintenance, alleviating the shortcomings of traditional manual inspections, improving automation and intelligence, and reducing downtime and repair costs associated with equipment failures.

[0054] On the other hand, the present application also provides a post-use detection and early warning method for a construction device, comprising:

[0055] A voltage sensor and a current sensor are arranged at the output end of the generator, and a vibration sensor and a temperature sensor are arranged on the bearing seat;

[0056] Collecting power information and operating condition information of the generator, wherein the power information includes output voltage and output current, and the operating condition information includes bearing vibration information and bearing temperature information;

[0057] Calculating the electrical property evaluation value based on the fluctuation value of the output voltage and the fluctuation value of the output current, determining whether to adjust the electrical property evaluation value based on the duration of the voltage fluctuation, and if it is determined to be adjusted, adjusting the electrical property evaluation value based on the duration of the voltage fluctuation and the duration of the voltage fluctuation interval to obtain a final electrical property evaluation value;

[0058] Calculating the mechanical evaluation value based on the bearing vibration information, determining whether to adjust the mechanical evaluation value based on the bearing temperature information, and if so, adjusting the mechanical evaluation value based on the temperature information to obtain a final mechanical evaluation value;

[0059] The final value of the electrical evaluation and the initial value of the mechanical evaluation are weighted and summed to obtain a total detection value, and an early warning is issued based on the total detection value.

[0060] It is understandable that the post-use detection and warning system and method for construction equipment provided in this application have the same beneficial effects and will not be described in detail here. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present invention. The same reference symbols are used throughout the drawings to represent the same components. In the drawings:

[0062] Figure 1 A functional block diagram of a post-use detection and warning system for a construction device provided by an embodiment of the present invention;

[0063] Figure 2 This is a flowchart of a post-use detection and early warning method for a construction device provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0064] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that, unless there is a conflict, the embodiments of the present disclosure and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.

[0065] In some embodiments of this application, see Figure 1 As shown, this embodiment provides a post-use detection and warning system for a construction device, comprising:

[0066] A sensor assembly, comprising a voltage sensor, a current sensor, a vibration sensor and a temperature sensor, wherein the voltage sensor and the current sensor are arranged at the output end of the generator, and the vibration sensor and the temperature sensor are arranged on the bearing seat;

[0067] A control module is configured to collect generator power information and operating condition information, obtain an electrical evaluation value of the generator based on the power information, obtain a mechanical evaluation value of the generator based on the operating condition information, and comprehensively evaluate the generator performance based on the electrical and mechanical evaluation values ​​and issue an early warning; the control module includes a collection unit, a processing unit, and an early warning unit;

[0068] The acquisition unit is used to collect power information and operating condition information of the generator, wherein the power information includes output voltage and output current, and the operating condition information includes bearing vibration information and bearing temperature information;

[0069] The processing unit is configured to calculate an electrical evaluation value based on the fluctuation value of the output voltage and the fluctuation value of the output current, determine whether to adjust the electrical evaluation value based on the duration of the voltage fluctuation, and if so, adjust the electrical evaluation value based on the duration of the voltage fluctuation and the duration of the voltage fluctuation interval to obtain a final electrical evaluation value;

[0070] The processing unit is further configured to calculate a mechanical evaluation value based on the bearing vibration information, determine whether to adjust the mechanical evaluation value based on the bearing temperature information, and if so, adjust the mechanical evaluation value based on the temperature information to obtain a final mechanical evaluation value.

[0071] The early warning unit is used to obtain the total detection value by weighted summing the final value of the electrical evaluation and the initial value of the mechanical evaluation, and to issue an early warning based on the total detection value.

[0072] As can be seen, this system, by integrating real-time monitoring of power and mechanical operating conditions, effectively enhances post-operation performance evaluation and fault warning capabilities. Voltage and current sensors monitor power fluctuations at the generator output, while vibration and temperature sensors track the operating status of the bearing housing in real time, providing critical mechanical operating data. By combining electrical and mechanical evaluation values, the system comprehensively assesses the generator's operating status and provides a comprehensive analysis of its electrical and mechanical performance. This dual monitoring mechanism promptly detects power fluctuations or mechanical anomalies, preventing potential failures and ensuring safe equipment operation and extending its service life. In particular, when voltage fluctuations or mechanical vibration exceed predetermined thresholds, the system intelligently adjusts the evaluation values ​​and issues warnings, prompting operators to take timely action, thereby improving safety and efficiency during construction. Ultimately, this comprehensive evaluation-based warning function provides a scientific basis for equipment maintenance, alleviating the shortcomings of traditional manual inspections, improving automation and intelligence, and reducing downtime and repair costs associated with equipment failures.

[0073] In some embodiments of the present application, when the processing unit is configured to calculate the electrical property evaluation value according to the fluctuation value of the output voltage and the fluctuation value of the output current, the processing unit includes:

[0074] Construct a voltage fluctuation value sequence and a current fluctuation value sequence within a unit time, and arrange the values ​​in the voltage fluctuation value sequence and the current fluctuation value sequence in descending order respectively;

[0075] Select the maximum voltage fluctuation value in the voltage fluctuation value sequence and the maximum current fluctuation value in the current fluctuation value sequence, and calculate the electrical evaluation value based on the maximum voltage fluctuation value, the number of voltage fluctuations, the maximum current fluctuation value, and the number of current fluctuations:

[0076]

[0077] In the above formula, Sd represents the electrical evaluation value, a represents the voltage fluctuation weight coefficient, NV represents the number of voltage fluctuations, Vk represents the kth voltage fluctuation value, b represents the current fluctuation weight coefficient, NI represents the number of current fluctuations, Vj represents the jth current fluctuation value, and a+b=1.

[0078] It is understandable that the processing unit in the present invention arranges the sequences of voltage fluctuation values ​​and current fluctuation values ​​in descending order, selects the maximum fluctuation value therefrom, and calculates the electrical evaluation value in combination with the number of fluctuations. The advantage of this method is that it can accurately quantify the severity and frequency of the generator power fluctuations. By setting the weight coefficients of the voltage and current fluctuations separately and performing weighted calculations based on the number of fluctuations, the degree of influence of different fluctuations can be effectively distinguished, thereby obtaining a more reasonable and detailed electrical evaluation value. This evaluation method not only improves the accuracy of power monitoring, but also adjusts the electrical evaluation value according to the actual fluctuation situation, enhances the system's early warning capability for power anomalies, helps to promptly detect potential faults, and ensures the stable operation of the equipment.

[0079] In some embodiments of the present application, when the processing unit is configured to determine whether to adjust the electrical property evaluation value according to the duration of the voltage fluctuation, the processing unit includes:

[0080] Set the maximum voltage fluctuation duration per unit time and collect the total voltage fluctuation duration per unit time. If the total voltage fluctuation duration is greater than the maximum voltage fluctuation duration, it is determined that the electrical evaluation value needs to be adjusted.

[0081] If the total duration of the voltage fluctuation is less than or equal to the maximum duration of the voltage fluctuation, it is determined that there is no need to adjust the electrical evaluation value.

[0082] It is understandable that the processing unit in the present invention determines whether the electrical evaluation value needs to be adjusted by setting the maximum voltage fluctuation duration and comparing it with the total voltage fluctuation duration per unit time. The advantage of this method is that it can flexibly adjust the evaluation value according to the duration of the voltage fluctuation, ensuring that the power system responds in a timely manner when a longer fluctuation occurs. If the duration of the voltage fluctuation exceeds the preset maximum value, it means that the equipment may face continuous power instability. The system will automatically adjust the electrical evaluation value to enhance the warning sensitivity. Conversely, if the fluctuation duration is short, there is no need to adjust the evaluation value, avoiding unnecessary false alarms. This method improves the accuracy of power monitoring, optimizes the timing of fault warnings, and ensures that the generator equipment can be promptly evaluated and maintained when the power fluctuation is abnormal.

[0083] In some embodiments of the present application, if the processing unit determines that an adjustment is required, the processing unit adjusts the electrical evaluation value according to the voltage fluctuation duration and the voltage fluctuation interval duration to obtain the electrical evaluation final value, including:

[0084] Construct a voltage fluctuation interval duration sequence Tx = {t1, t2, …, tn} within a unit time, calculate the impact factor based on the interval duration value of each interval in the interval duration sequence and the total duration of voltage fluctuation, and adjust the electrical evaluation value based on the impact factor;

[0085] The impact factor is calculated using the following formula:

[0086]

[0087] In the above formula, F represents the impact factor, n represents the number of values ​​in the interval duration sequence, ti represents the i-th interval duration, T represents the total duration of voltage fluctuation, and wi represents the weight of each interval duration ti.

[0088] It can be understood that the processing unit in the present invention further accurately adjusts the electrical evaluation value by constructing a voltage fluctuation interval duration sequence and calculating the impact factor, which can comprehensively consider the distribution of voltage fluctuation interval duration, rather than just focusing on the total duration of the fluctuation. By adjusting each interval duration through weight distribution, the frequency of voltage fluctuations and their impact on equipment can be reflected more carefully, thereby more accurately evaluating the stability of the power system. When the interval duration of voltage fluctuations is long, it may indicate that the equipment load changes greatly. The adjustment of the impact factor can increase the correction strength of the electrical evaluation value and improve the system's early warning ability for potential faults. This method effectively avoids the misjudgment caused by simple fluctuation duration judgment, making the electrical evaluation more scientific and accurate, and helping to promptly detect abnormal conditions of the power system and take effective preventive measures.

[0089] In some embodiments of the present application, if the processing unit determines that an adjustment is required, the processing unit adjusts the electrical property evaluation value according to the voltage fluctuation duration and the voltage fluctuation interval duration to obtain the final electrical property evaluation value, further comprising:

[0090] Set the minimum and maximum impact factors;

[0091] If the impact factor is less than the minimum impact factor, the electrical property evaluation value is adjusted using the first adjustment coefficient;

[0092] If the impact factor is greater than or equal to the minimum impact factor and less than or equal to the maximum impact factor, the electrical evaluation value is adjusted using the second adjustment coefficient;

[0093] If the impact factor is greater than the maximum impact factor, the electrical evaluation value is adjusted using the third adjustment coefficient;

[0094] The first adjustment coefficient is smaller than the second adjustment coefficient, and the second adjustment coefficient is smaller than the third adjustment coefficient.

[0095] It can be understood that the processing unit in the present invention can achieve a more flexible and accurate adjustment mechanism by setting the minimum and maximum values ​​of the influencing factors and adjusting the electrical evaluation values ​​with different adjustment coefficients according to different ranges of the influencing factors. By adjusting the evaluation values ​​in a graded manner according to the size of the influencing factors, the impact of different degrees of voltage fluctuations on equipment performance can be effectively distinguished. If the influencing factor is small, it indicates that the voltage fluctuation is relatively minor, and the system adjusts it through a smaller adjustment coefficient to avoid overreaction; if the influencing factor is large, it indicates that the fluctuation is more severe, and the system corrects it through a larger adjustment coefficient, thereby reflecting the instability of the power system more promptly. This hierarchical adjustment mechanism improves the meticulousness of the evaluation, avoids misjudgment caused by excessive or insufficient adjustment, ensures the accuracy and sensitivity of the electrical evaluation value, helps to better predict potential faults of the generator, and enhances the system's early warning capabilities and maintenance efficiency.

[0096] In some embodiments of the present application, the processing unit is further configured to calculate a mechanical evaluation value based on bearing vibration information, including:

[0097] Preset the standard vibration value, collect the vibration waveform output by the vibration sensor within a unit time, calculate the vibration average value, and calculate the mechanical evaluation value based on the vibration average value and the vibration peak value:

[0098] Sj=k*Aavg*e Af / A0 ;

[0099] In the above formula, Sj represents the mechanical evaluation value, k represents the adjustment coefficient, Aavg represents the vibration average value, Af represents the vibration peak value, and A0 represents the standard vibration value.

[0100] It can be understood that the processing unit in the present invention calculates the ratio of the vibration average value to the vibration peak value, and calculates the mechanical evaluation value in combination with the preset standard vibration value, which can accurately reflect the health status of the mechanical equipment. By comparing the vibration average value and peak value with the standard vibration value, the vibration level of the equipment and the potential risk of mechanical failure can be effectively evaluated. The combination of the vibration average value and peak value makes the evaluation more comprehensive, and the standard vibration value as a benchmark can help the system more accurately identify whether there is an abnormality. The introduction of the adjustment coefficient allows for flexible adjustment of the vibration characteristics under different equipment or working conditions, further improving the accuracy and adaptability of the evaluation value. Through this mechanism, the system can more accurately monitor the mechanical status of key components such as bearings, identify early failures or potential problems in a timely manner, thereby avoiding major damage and shutdown of the equipment, and improving the operational reliability and maintenance efficiency of the equipment.

[0101] In some embodiments of the present application, the processing unit is further configured to determine whether to adjust the mechanical evaluation value based on the bearing temperature information, including:

[0102] The maximum bearing temperature is preset. If the bearing temperature is less than or equal to the maximum bearing temperature, it is determined that there is no need to adjust the mechanical evaluation value;

[0103] If the bearing temperature is greater than the maximum bearing temperature, it is determined that the mechanical evaluation value needs to be adjusted.

[0104] It can be understood that the processing unit in the present invention can effectively prevent mechanical failures caused by excessively high temperatures by setting the maximum bearing temperature and determining whether to adjust the mechanical evaluation value based on the comparison between the actual temperature and the preset value. Bearing temperature is an important parameter that reflects mechanical wear and operating status. When the bearing temperature exceeds the preset maximum temperature, it may mean that the bearing is overheating or there are problems such as poor lubrication, which in turn leads to a decline in mechanical performance or failure. Therefore, the system adjusts the mechanical evaluation value in a timely manner by setting the temperature threshold, thereby improving the early warning capability for potential failures. When the bearing temperature is normal, the evaluation value does not need to be adjusted, which avoids unnecessary false alarms, enhances the accuracy of mechanical evaluation, and enables the system to respond to temperature anomalies more sensitively and take maintenance measures in advance, thereby effectively ensuring the safe operation of the equipment and extending its service life.

[0105] In some embodiments of the present application, the processing unit is further configured to adjust the mechanical evaluation value according to the temperature information if it is determined to be an adjustment, and obtain a final mechanical evaluation value, including:

[0106] Setting a first temperature and a second temperature, wherein the first temperature is lower than the second temperature;

[0107] If the bearing temperature is less than the first temperature, the mechanical evaluation value is adjusted by the first adjustment coefficient;

[0108] If the bearing temperature is greater than or equal to the first temperature and less than or equal to the second temperature, the mechanical evaluation value is adjusted by a second adjustment coefficient;

[0109] If the bearing temperature is greater than the second temperature, the mechanical evaluation value is adjusted by a third adjustment coefficient;

[0110] The first adjustment coefficient is greater than the second adjustment coefficient, and the second adjustment coefficient is greater than the third adjustment coefficient.

[0111] It can be understood that the processing unit in the present invention can more accurately reflect the impact of bearing temperature changes on mechanical properties by setting multiple temperature thresholds and using different adjustment coefficients to adjust the mechanical evaluation value according to different bearing temperature intervals. By setting the first temperature and the second temperature interval, the judgment of the mechanical state in different temperature ranges can be refined to avoid overreaction or underreaction to temperature changes. If the temperature is low, the evaluation value is increased by a larger adjustment coefficient (first adjustment coefficient) to reflect that the equipment is operating in a relatively stable state; when the temperature is close to the normal operating range, a smaller adjustment coefficient is used for correction; and when the temperature is too high, an even smaller adjustment coefficient is used for adjustment, thereby suppressing the potential risks caused by overheating. Such a hierarchical adjustment mechanism makes the system more flexible and can dynamically adjust the evaluation results according to actual temperature changes, thereby improving the accuracy of fault warnings and the timeliness of responses, effectively protecting the equipment from damage caused by excessively high temperatures, and extending the service life of the equipment.

[0112] In some embodiments of the present application, the early warning unit is configured to obtain a total detection value by weighted summing the final value of the electrical evaluation and the initial value of the mechanical evaluation. When issuing an early warning based on the total detection value, the early warning includes:

[0113] Sz=a*Sd1+β*Sj1;

[0114] In the above formula, Sz represents the total test value, α represents the weight coefficient of the final value of the electrical evaluation, Sd1 represents the final value of the electrical evaluation, β represents the weight coefficient of the final value of the mechanical evaluation, and Sj1 represents the final value of the mechanical evaluation;

[0115] Set a first total value and a second total value, and the first total value is smaller than the second total value;

[0116] If the total detection value is less than the first total value, a first-level warning will be issued;

[0117] If the total detection value is greater than or equal to the first total value and less than or equal to the second total value, a second-level warning is issued;

[0118] If the total detection value is greater than the second total value, a third-level warning will be issued;

[0119] Among them, the warning levels from low to high are level one warning, level two warning and level three warning.

[0120] It can be understood that the early warning unit in the present invention obtains the total detection value by weighted summing the final value of the electrical evaluation and the final value of the mechanical evaluation, and sets different early warning levels according to the total value. It can dynamically adjust the early warning response according to the comprehensive evaluation results, thereby more accurately predicting the health status of the equipment. By setting weight coefficients (α and β) for the electrical evaluation and the mechanical evaluation respectively, the degree of their influence in the overall evaluation can be flexibly adjusted according to different types of failure risks. By setting the interval between the first total value and the second total value, different early warning levels can be set for abnormal situations of different degrees, from level one warning to level three warning, to ensure that the system can provide timely feedback and corresponding processing measures according to the actual status of the equipment, which helps to identify potential problems at an early stage and take appropriate countermeasures to prevent faults from escalating or causing greater damage, thereby improving equipment reliability, reducing downtime, and effectively reducing maintenance costs.

[0121] On the other hand, see Figure 2 As shown, the present application also provides a post-use detection and early warning method for a construction device, which is applied to the post-use detection and early warning system for the construction device, and includes the following steps:

[0122] S100, placing a voltage sensor and a current sensor at the output end of the generator, and placing a vibration sensor and a temperature sensor on the bearing seat;

[0123] S200, collecting power information and operating condition information of the generator, wherein the power information includes output voltage and output current, and the operating condition information includes bearing vibration information and bearing temperature information;

[0124] S300, calculating an electrical property evaluation value based on the fluctuation value of the output voltage and the fluctuation value of the output current, determining whether to adjust the electrical property evaluation value based on the duration of the voltage fluctuation, and if so, adjusting the electrical property evaluation value based on the duration of the voltage fluctuation and the duration of the voltage fluctuation interval to obtain a final electrical property evaluation value;

[0125] S400, calculating a mechanical evaluation value based on bearing vibration information, determining whether to adjust the mechanical evaluation value based on bearing temperature information, and if so, adjusting the mechanical evaluation value based on the temperature information to obtain a final mechanical evaluation value;

[0126] S500: Obtain a total detection value by weighted summing the final value of the electrical evaluation and the initial value of the mechanical evaluation, and issue an early warning based on the total detection value.

[0127] It is understood that the detection and early warning method provided by the present invention effectively improves the accuracy and timeliness of equipment fault early warning by comprehensively collecting and analyzing power information and operating condition information, combined with the dynamic adjustment of electrical evaluation values ​​and mechanical evaluation values. Specifically, the method can fully understand the operating status of the equipment by collecting the output voltage and current of the generator as well as the vibration and temperature information of the bearings. The electrical evaluation value reflects the health of the power system by analyzing the voltage and current fluctuations, and further accurately adjusts the evaluation results by combining the influencing factors of the voltage fluctuation duration and interval duration. The mechanical evaluation value evaluates the status of the mechanical part by combining bearing vibration information and temperature information, and dynamically corrects the evaluation value according to temperature changes to avoid the impact of problems such as overheating. Finally, the electrical and mechanical evaluation results are combined, and a weighted sum is performed to obtain the total detection value. Different levels of early warning are issued based on the total value. This can achieve real-time monitoring of multiple dimensions and parameters, timely detect potential equipment failures and issue early warnings, reduce downtime, reduce maintenance costs, and improve the operational safety and reliability of the equipment.

[0128] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may take the form of a complete hardware embodiment, a complete software embodiment, or a combination of software and hardware embodiments. Furthermore, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0129] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems) and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0130] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1The function specified in one or more boxes.

[0131] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0132] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the scope of protection of the claims of the present invention.

Claims

1. A post-use detection and warning system for a construction device, characterized in that: include: A sensor assembly, comprising a voltage sensor, a current sensor, a vibration sensor and a temperature sensor, wherein the voltage sensor and the current sensor are arranged at the output end of the generator, and the vibration sensor and the temperature sensor are arranged on the bearing seat; a control module configured to collect power information and operating condition information of the generator, obtain an electrical evaluation value of the generator based on the power information, obtain a mechanical evaluation value of the generator based on the operating condition information, and comprehensively evaluate the performance of the generator based on the electrical and mechanical evaluation values ​​and issue an early warning; wherein the control module includes a collection unit, a processing unit, and an early warning unit; The acquisition unit is used to acquire power information and operating condition information of the generator, wherein the power information includes output voltage and output current, and the operating condition information includes bearing vibration information and bearing temperature information; The processing unit is configured to calculate the electrical evaluation value based on the fluctuation value of the output voltage and the fluctuation value of the output current, determine whether to adjust the electrical evaluation value based on the duration of the voltage fluctuation, and if it is determined to be adjusted, adjust the electrical evaluation value based on the duration of the voltage fluctuation and the duration of the voltage fluctuation interval to obtain a final electrical evaluation value; The processing unit is further configured to calculate the mechanical evaluation value based on the bearing vibration information, determine whether to adjust the mechanical evaluation value based on the bearing temperature information, and if so, adjust the mechanical evaluation value based on the temperature information to obtain a final mechanical evaluation value. The early warning unit is used to obtain a total detection value by weighted summing the final value of the electrical evaluation and the initial value of the mechanical evaluation, and to issue an early warning based on the total detection value; When the processing unit is used to calculate the electrical property evaluation value according to the fluctuation value of the output voltage and the fluctuation value of the output current, it includes: Constructing a voltage fluctuation value sequence and a current fluctuation value sequence within a unit time, and arranging the values ​​in the voltage fluctuation value sequence and the current fluctuation value sequence in descending order respectively; The maximum voltage fluctuation value in the voltage fluctuation value sequence and the maximum current fluctuation value in the current fluctuation value sequence are selected, and the electrical property evaluation value is calculated according to the maximum voltage fluctuation value, the number of voltage fluctuations, the maximum current fluctuation value, and the number of current fluctuations: ； In the above formula, Sd represents the electrical evaluation value, a represents the voltage fluctuation weight coefficient, NV represents the number of voltage fluctuations, Vk represents the kth voltage fluctuation value, b represents the current fluctuation weight coefficient, NI represents the number of current fluctuations, Vj represents the jth current fluctuation value, and a+b=1; When the processing unit is used to determine whether to adjust the electrical property evaluation value according to the duration of the voltage fluctuation, it includes: Setting a maximum voltage fluctuation duration per unit time, collecting a total voltage fluctuation duration per unit time, and determining that the electrical evaluation value needs to be adjusted if the total voltage fluctuation duration is greater than the maximum voltage fluctuation duration; If the total duration of the voltage fluctuation is less than or equal to the maximum duration of the voltage fluctuation, it is determined that the electrical property evaluation value does not need to be adjusted; The processing unit is configured to adjust the electrical evaluation value according to the voltage fluctuation duration and the voltage fluctuation interval duration if it is determined that the adjustment is required, to obtain a final electrical evaluation value, including: Constructing a voltage fluctuation interval duration sequence Tx={t1, t2, …, tn} within a unit time, calculating an impact factor based on each interval duration value in the interval duration sequence and the total duration of the voltage fluctuation, and adjusting the electrical property evaluation value based on the impact factor; The impact factor is calculated by the following formula: ； In the above formula, F represents the impact factor, n represents the number of values ​​in the interval duration sequence, ti represents the i-th interval duration, T represents the total duration of voltage fluctuation, and wi represents the weight of each interval duration ti; The processing unit is configured to adjust the electrical evaluation value according to the voltage fluctuation duration and the voltage fluctuation interval duration if it is determined that the adjustment is required, and to obtain a final electrical evaluation value, further comprising: Set the minimum and maximum impact factors; If the impact factor is less than the minimum impact factor, adjusting the electrical property evaluation value by a first adjustment coefficient; If the impact factor is greater than or equal to the minimum impact factor and less than or equal to the maximum impact factor, the electrical property evaluation value is adjusted by a second adjustment coefficient; If the impact factor is greater than the maximum impact factor, adjusting the electrical property evaluation value by a third adjustment coefficient; Wherein, the first adjustment coefficient is smaller than the second adjustment coefficient, and the second adjustment coefficient is smaller than the third adjustment coefficient; The processing unit is further configured to calculate the mechanical evaluation value according to the bearing vibration information, including: A standard vibration value is preset, a vibration waveform output by a vibration sensor within a unit time is collected, an average vibration value is calculated, and the mechanical evaluation value is calculated based on the average vibration value and the peak vibration value: ； In the above formula, Sj represents the mechanical evaluation value, k represents the adjustment coefficient, Aavg represents the average vibration value, Af represents the peak vibration value, and A0 represents the standard vibration value.

2. The post-use detection and warning system for construction equipment according to claim 1, characterized in that: The processing unit is further configured to determine whether to adjust the mechanical evaluation value according to the bearing temperature information, including: Preset a maximum bearing temperature, and if the bearing temperature is less than or equal to the maximum bearing temperature, determine that there is no need to adjust the mechanical evaluation value; If the bearing temperature is greater than the maximum bearing temperature, it is determined that the mechanical evaluation value needs to be adjusted.

3. The post-use detection and warning system for construction equipment according to claim 2, characterized in that: The processing unit is further configured to adjust the mechanical evaluation value according to the temperature information if it is determined to be an adjustment, and obtain a final mechanical evaluation value, including: Setting a first temperature and a second temperature, wherein the first temperature is lower than the second temperature; If the bearing temperature is lower than the first temperature, adjusting the mechanical evaluation value by a first adjustment coefficient; If the bearing temperature is greater than or equal to the first temperature and less than or equal to the second temperature, adjusting the mechanical evaluation value by a second adjustment coefficient; If the bearing temperature is greater than the second temperature, adjusting the mechanical evaluation value by a third adjustment coefficient; The first adjustment coefficient is greater than the second adjustment coefficient, and the second adjustment coefficient is greater than the third adjustment coefficient.

4. The post-use detection and warning system for construction equipment according to claim 3, characterized in that: The early warning unit is used to obtain a total detection value by weighted summing the final value of the electrical evaluation and the initial value of the mechanical evaluation. When issuing an early warning based on the total detection value, it includes: ； In the above formula, Sz represents the total test value, α represents the weight coefficient of the final value of the electrical evaluation, Sd1 represents the final value of the electrical evaluation, β represents the weight coefficient of the final value of the mechanical evaluation, and Sj1 represents the final value of the mechanical evaluation; Set a first total value and a second total value, and the first total value is smaller than the second total value; If the total detection value is less than the first total value, a first-level warning is issued; If the total detection value is greater than or equal to the first total value and less than or equal to the second total value, a second-level warning is issued; If the total detection value is greater than the second total value, a third-level warning is issued; Among them, the warning levels from low to high are level one warning, level two warning and level three warning.

5. A post-use detection and early warning method for a construction device, applied to the post-use detection and early warning system for a construction device according to any one of claims 1 to 4, characterized in that: include: A voltage sensor and a current sensor are arranged at the output end of the generator, and a vibration sensor and a temperature sensor are arranged on the bearing seat; Collecting power information and operating condition information of the generator, wherein the power information includes output voltage and output current, and the operating condition information includes bearing vibration information and bearing temperature information; Calculating the electrical property evaluation value based on the fluctuation value of the output voltage and the fluctuation value of the output current, determining whether to adjust the electrical property evaluation value based on the duration of the voltage fluctuation, and if it is determined to be adjusted, adjusting the electrical property evaluation value based on the duration of the voltage fluctuation and the duration of the voltage fluctuation interval to obtain a final electrical property evaluation value; Calculating the mechanical evaluation value based on the bearing vibration information, determining whether to adjust the mechanical evaluation value based on the bearing temperature information, and if so, adjusting the mechanical evaluation value based on the temperature information to obtain a final mechanical evaluation value; The final value of the electrical evaluation and the initial value of the mechanical evaluation are weighted and summed to obtain a total detection value, and an early warning is issued based on the total detection value.

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