Fault detection system for mobile screening station

Abstract

The invention discloses a fault detection system for a mobile screening station, and relates to the field of fault detection, the fault detection system comprises a main control center, the main control center is in communication connection with a data acquisition module, a data processing module, a data analysis module and a feedback alarm module; the data acquisition module is used for acquiring operation data of the mobile screening station to obtain corresponding screening data; the data processing module is used for processing the obtained screening data to obtain a corresponding abnormal data set, and the abnormal data set comprises an abnormal particle size data set and an abnormal amplitude data set; the data analysis module is used for performing fault analysis according to the received abnormal data set and generating a corresponding fault diagnosis result; the feedback alarm module is used for performing corresponding visual alarm according to the fault diagnosis result; the fault monitoring of the mobile screening station can be effectively realized, and the screening efficiency of the mobile screening station is improved.

Description

Technical Field

[0001] The invention relates to the field of fault detection, and in particular to a fault detection system for a mobile screening station. Background Art

[0002] As people's awareness of environmental protection increases, the demand for recycling and reuse of construction waste is gradually increasing. The introduction of mobile screening stations allows construction waste to be screened and classified on site, which improves the reuse rate of waste and reduces resource waste and environmental pollution. In the actual use process of mobile screening stations in the prior art, most of them are used in combination with multiple units; they are composed of multiple conveyors, multiple screening machines, etc. Due to the large number of components, the reliability and operating rate of the mobile screening station are low. Traditional fault detection of mobile screening stations mainly relies on manual inspections and self-diagnosis of the equipment itself. Manual inspections have problems of poor timeliness and inaccurate detection. Although the self-diagnosis of the equipment itself can detect some faults, there are still many limitations. To achieve a significant improvement in the reliability and screening efficiency of the mobile screening station, we provide a fault detection system for a mobile screening station. Summary of the invention

[0003] The object of the present invention can be achieved by the following technical solutions: A fault detection system for a mobile screening station, comprising a main control center, wherein the main control center is communicatively connected with a data acquisition module, a data processing module, a data analysis module and a feedback alarm module; The data acquisition module is used to collect the operation data of the mobile screening station to obtain corresponding screening data; The data processing module is used to process the obtained screening data to obtain a corresponding abnormal data set, wherein the abnormal data set includes an abnormal particle size data set and an abnormal amplitude data set; The data analysis module is used to perform fault analysis based on the received abnormal data set and generate corresponding fault diagnosis results; The feedback alarm module is used to issue corresponding visual alarms according to the fault diagnosis results.

[0004] Furthermore, the data acquisition module collects the operation data of the mobile screening station, and the process of obtaining the corresponding screening data includes: The data acquisition module includes an image acquisition terminal, a weight data acquisition terminal and an amplitude data acquisition terminal, which are respectively used to periodically collect the screening data generated during the operation of the mobile screening station, and the screening data includes the image information, weight data and amplitude data of the material at the discharge port of the screening station; and are placed at different positions of the mobile screening station as required.

[0005] Furthermore, the weight data collection terminal is connected to the automatic weighing equipment of the screening station through an interface, collects the data recorded by the automatic weighing equipment, and obtains the material weight data of the corresponding discharge port.

[0006] Furthermore, the data processing module processes the screening data to obtain a corresponding abnormal particle size data set, including: The contrast and brightness of the collected material image information are adjusted. After the adjustment is completed, the material and the background in the image are separated, and the features of the separated particles are extracted. The extracted features include the size and shape of the material. The particle size of the material is calculated based on the extracted features to obtain the particle size data of the corresponding material; According to the obtained particle size data, a corresponding particle size coefficient and a particle size average value are obtained, a particle size threshold is set according to the obtained particle size coefficient and the particle size average value, and the obtained particle size data is compared with the particle size threshold; If the particle size data is lower than the particle size threshold, the corresponding particle size data is marked as abnormal particle size data, and the marked abnormal particle size data is integrated to obtain a corresponding abnormal particle size data set.

[0007] Furthermore, the data processing module processes the obtained screening data to obtain an abnormal amplitude data set, which includes: Reading the amplitude data in the screening data, and simultaneously obtaining the amplitude specification of the mobile screening station, traversing the received amplitude data; and comparing the amplitude data with the amplitude specification; If the amplitude data exceeds the amplitude specification, the corresponding amplitude data will be marked and recorded as abnormal amplitude data; All marked abnormal amplitude data are summarized to obtain an abnormal amplitude data set.

[0008] Furthermore, the process of the data analysis module analyzing the obtained abnormal particle size data set includes: Read the obtained abnormal particle size data set to obtain the number of corresponding abnormal particle size data; Set a quantity threshold. If the number of abnormal particle size data is lower than the quantity threshold, it indicates that the mobile screening station is operating normally. If the number of abnormal particle size data is not less than the number threshold, the corresponding abnormal particle size data set is made into a data chart according to the collection time; and it is identified; Obtain the peak point in the data chart, and determine whether there is a broken point in the screen of the mobile screening station based on it. If there is a broken point, generate corresponding damage information; if there is no broken point, generate corresponding blockage information; The abnormal particle size data are divided into several intervals, the number of abnormal particle size data in each interval is counted, and the number of obtained interval abnormal particle size data is compared with the number of total abnormal particle size data to obtain a corresponding number ratio; A particle size threshold is set. If the number ratio is higher than the particle size threshold, the corresponding screen is judged to have cracks or deformation, and wear information is generated.

[0009] Furthermore, the process of the data analysis module analyzing the obtained abnormal amplitude data set includes: Set the fluctuation threshold, read the obtained abnormal amplitude data set, and obtain the corresponding amplitude fluctuation coefficient; If the amplitude fluctuation coefficient is not lower than the fluctuation threshold, the vibration equipment of the mobile screening station is judged to be faulty, and corresponding vibration equipment abnormality information is generated; If the amplitude fluctuation coefficient is lower than the fluctuation threshold, it is judged that the screen support of the mobile screening station is loose, and corresponding support abnormality information is generated.

[0010] Furthermore, the process of the data analysis module analyzing the material weight data of the discharge port in the collected screening data includes: Set the weight threshold range, obtain the material weight data of the discharge port of the screening station recorded in several historical periods, and calculate the weight deviation g based on the obtained material weight data, and at the same time calculate the average value G of the material weight data of the discharge port collected in several recent periods 0 , predict the material weight of the next cycle, and record the predicted material weight of the next cycle as G 预 ; Compare the predicted weight of the next period of materials with the weight threshold range; if the predicted weight of the next period of materials is within the threshold range, it indicates that the screening station is operating normally; If the predicted material weight of the next cycle is outside the threshold range, it indicates that the screening station is operating abnormally and abnormal operation information is generated.

[0011] Furthermore, the process of the feedback alarm module performing a corresponding visual alarm according to the fault diagnosis result includes: The information feedback unit includes a feedback unit and a display unit; When the feedback alarm receives the blockage information and the wear information, it is judged as a primary fault, and the feedback unit is used to initiate feedback to the main control center, and a primary fault alarm is issued, and the fault information is displayed through the display unit until the fault is repaired or manually closed, and the fault alarm stops and the fault information is eliminated; When the feedback alarm receives the abnormal information of the bracket, it is judged as a secondary fault, and the feedback unit is used to initiate feedback to the main control center, a secondary fault alarm is issued, and the fault information is displayed through the display unit until the fault is eliminated or manually closed, the fault alarm stops and the fault information is eliminated; When the feedback alarm receives abnormal information of the vibration equipment, it is judged as a third-level fault, and the feedback unit is used to initiate feedback to the main control center to issue a third-level fault alarm, and the fault information is displayed through the display unit at the same time until the fault is repaired or manually closed, the fault alarm stops and the fault information is eliminated; When the feedback alarm receives damage information or abnormal operation information, it is judged as a level 4 fault, and the feedback unit is used to initiate feedback to the main control center to issue a level 4 fault alarm, and the fault information is displayed through the display unit until the fault is eliminated, the alarm light is turned off, and the fault information is eliminated; Furthermore, the fault levels are divided into level one fault < level two fault < level three fault < level four fault.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: by utilizing multiple acquisition terminals to collect the screening data of the mobile screening station, the main control center obtains the screening data of the mobile screening station in real time, and by processing and analyzing the screening data of the mobile screening station, it is possible to timely discover and accurately locate the faults existing in the screening station, and to give feedback alarms thereof, and through the feedback alarms, the user can timely understand the fault conditions and take corresponding measures, thereby effectively reducing the failure risk of the mobile screening station, improving the screening efficiency and reducing the production downtime. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a schematic diagram of the present invention. DETAILED DESCRIPTION

[0014] like Figure 1 As shown, a fault detection system for a mobile screening station includes a main control center, and the main control center is communicatively connected to a data acquisition module, a data processing module, a data analysis module, and a feedback alarm module; The data acquisition module is used to collect the operation data of the mobile screening station to obtain corresponding screening data; The data processing module is used to process the obtained screening data to obtain a corresponding abnormal data set, wherein the abnormal data set includes an abnormal particle size data set and an abnormal amplitude data set; The data analysis module is used to perform fault analysis based on the received abnormal data set and generate corresponding fault diagnosis results; The feedback alarm module is used to issue corresponding visual alarms according to the fault diagnosis results; It should be further explained that, in the specific implementation process, the data acquisition module collects the operation data of the mobile screening station, and the process of obtaining the corresponding screening data includes: The data acquisition module is composed of several different data acquisition terminals, including an image acquisition terminal, an amplitude data acquisition terminal and a weight data acquisition terminal, which are respectively used to periodically acquire corresponding screening data, and the screening data includes material image information at the discharge port of the screening station, amplitude data of the screen and material weight data at the discharge port; the data acquisition terminals are placed at different positions in the mobile screening station as required; It should be further explained that, in the specific implementation process, the weight data collection terminal is connected to the automatic weighing equipment of the screening station through an interface, collects the data recorded by the automatic weighing equipment, and obtains the material weight data of the corresponding discharge port; It should be further explained that, in the specific implementation process, the mobile screening station includes multiple discharge ports, and the present invention takes a certain discharge port of the mobile screening station as an example; It should be further explained that, in the specific implementation process, the data processing module is used to process the obtained screening data, and the process of obtaining the corresponding abnormal data set includes: The abnormal data set includes an abnormal particle size data set and an abnormal amplitude data set; The data processing module includes a particle size data processing unit and an amplitude data processing unit; It should be further explained that, in the specific implementation process, the process of the particle size data processing unit processing the collected material image information includes: The contrast and brightness of the acquired material image are adjusted. After the adjustment is completed, the material and the background in the image are separated, and the features of the separated particles are extracted. The extracted features include the size and shape of the material. The particle size of the material is calculated based on the extracted features to obtain the particle size data of the corresponding material; Traverse the obtained particle size data, number the obtained particle size data, record it as i=1,2,...,n, n is an integer, and n>0; then the corresponding particle size data set is X i =(X 1 , X 2 , ..., X n ); Calculate the particle size coefficient L of the discharge port respectively 出 ; in, ; In the formula, μ 1 The average value of all particle size data collected in the current cycle; Obtain the normal particle size data set recorded during the normal operation of the screening station stored in several historical periods; calculate the corresponding average value L, and set the particle size threshold range, where the particle size threshold range is (LL 出 , L+L 出 ); Compare the collected particle size data with the set particle size threshold; If the particle size data is within the particle size threshold range, it indicates that the particle size data of the particles at the discharge port of the screening station meets the screening requirements, and the corresponding particle size data is recorded as normal particle size data; If the particle size data is outside the particle size threshold range, it indicates that the particle size data of the particles at the discharge port of the screening station does not meet the screening requirements, and the data processing module marks the corresponding particle size data as abnormal particle size data; After all the particle size data are compared, the normal particle size data are packaged to obtain a normal particle size data set, and stored in the database; the abnormal particle size data are packaged to obtain an abnormal particle size data set; It should be further explained that, in a specific implementation process, the process of the amplitude data processing unit processing the collected amplitude data includes: Read the amplitude data in the screening data, and simultaneously obtain the amplitude specification of the mobile screening station, the amplitude specification being one of the attribute parameters of the screening station, and traverse the received amplitude data; compare the amplitude data with the amplitude specification, if the amplitude data is within the amplitude specification, it indicates that the vibration data is normal, and the data is recorded as normal amplitude data; if the amplitude data is outside the amplitude specification, the corresponding amplitude data is marked, and the data is recorded as abnormal amplitude data; Summarize all marked abnormal amplitude data to obtain an abnormal amplitude data set; It should be further explained that, in the specific implementation process, the data analysis module performs fault analysis based on the obtained abnormal data set, and the process of obtaining the corresponding fault diagnosis result includes: The fault diagnosis results include blockage information, wear information, damage information, bracket abnormality information, vibration equipment abnormality information and operation abnormality information; Read the obtained abnormal particle size data set to obtain the number of corresponding abnormal particle size data; Set a quantity threshold. If the number of abnormal particle size data is lower than the quantity threshold, it indicates that the mobile screening station is operating normally. If the number of abnormal particle size data is not less than the number threshold, the corresponding abnormal particle size data set is made into a data chart according to the collection time; and it is identified; Get the peak point of the particle size in the chart and compare it with the aperture of the sieve; If the particle size peak point is not higher than the aperture of the sieve, indicating that the corresponding sieve is not damaged, it is determined that the corresponding sieve is blocked, and the data analysis module generates blockage information; If the particle size peak point is higher than the aperture of the sieve, it is determined that the corresponding sieve is damaged, and the data analysis module generates damage information; The acquired abnormal particle size data set is divided into several intervals, the number of abnormal particle size data in each interval is counted, and the number of acquired interval abnormal particle size data is compared with the number of total abnormal particle size data to obtain a corresponding number ratio; A particle size threshold is set, and if the obtained number ratio is lower than the particle size threshold, other methods are used to evaluate the sieve; If the obtained quantity ratio is not lower than the particle size threshold, it is determined that the corresponding screen is deformed or cracked, and the data analysis module generates wear information; The amplitude data in the obtained abnormal amplitude data set are numbered and recorded as a, where a=1, 2, ..., k, k is an integer, and k>0; the corresponding abnormal amplitude data set is Z a =(Z 1 , Z 2 , ..., Z k ); Calculate the corresponding amplitude fluctuation coefficient H based on the obtained abnormal amplitude data set; in ; Set fluctuation thresholds; If the amplitude fluctuation coefficient H is not lower than the fluctuation threshold, indicating that the abnormal amplitude data presents high-frequency fluctuations, it is determined that the vibration equipment of the mobile screening station is faulty, and the data analysis module generates abnormal information of the vibration equipment; If the amplitude fluctuation coefficient H is lower than the fluctuation threshold, indicating that the abnormal amplitude data presents low-frequency fluctuations, it is judged that the support of the screen in the screening station is loose, and the data analysis module generates support abnormality information; Obtain the material weight data at the discharge port of the screening station recorded in the recent historical cycles, and calculate the weight deviation g based on the obtained material weight data, and at the same time calculate the average value G of the material weight data at the discharge port collected in the recent cycles 0 , predict the material weight of the next cycle, and record the predicted material weight of the next cycle as G 预 ; The material weight data obtained by the data acquisition unit is numbered as c, where c=1,2,...,h, h is an integer and h>0; the corresponding material weight data is G c =(G 1 , G 2 , ..., G h ) in ; G 预 =α×G 0 + (1-α)×G 现 ; In the formula, G 现 The weight of the material collected for the current cycle; α is the weight ratio, and the specific value of α depends on actual needs; Set the weight threshold, where the weight threshold range is (G 现 -g,G 现 +g), compare the predicted material weight of the next period with the threshold; If the predicted material weight of the next cycle is within the threshold range, it indicates that the screening station is operating normally; If the predicted material weight of the next cycle is outside the threshold range, it indicates that the screening station is operating abnormally and abnormal operation information is generated.

[0015] The process of the feedback alarm module performing corresponding visual alarm according to the fault diagnosis result includes: The information feedback unit includes a feedback unit and a display unit; When the feedback alarm receives the blockage information and the wear information, it is judged as a primary fault, and the feedback unit is used to initiate feedback to the main control center, and a primary fault alarm is issued, and the fault information is displayed through the display unit until the fault is repaired or manually closed, and the fault alarm stops and the fault information is eliminated; When the feedback alarm receives the abnormal information of the bracket, it is judged as a secondary fault, and the feedback unit is used to initiate feedback to the main control center, a secondary fault alarm is issued, and the fault information is displayed through the display unit until the fault is eliminated or manually closed, the fault alarm stops and the fault information is eliminated; When the feedback alarm receives abnormal information of the vibration equipment, it is judged as a third-level fault, and the feedback unit is used to initiate feedback to the main control center to issue a third-level fault alarm, and the fault information is displayed through the display unit at the same time until the fault is repaired or manually closed, the fault alarm stops and the fault information is eliminated; When the feedback alarm receives damage information or abnormal operation information, it is judged as a level 4 fault, and the feedback unit is used to initiate feedback to the main control center to issue a level 4 fault alarm, and the fault information is displayed through the display unit until the fault is eliminated, the alarm light is turned off, and the fault information is eliminated; It should be further explained that, in the specific implementation process, the fault levels are divided into level 1 fault < level 2 fault < level 3 fault < level 4 fault.

[0016] The above embodiments are only used to illustrate the technical method of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical method of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical method of the present invention.

Claims

1. A fault detection system for a mobile screening station, comprising a main control center, characterized in that: The main control center is communicatively connected with a data acquisition module, a data processing module, a data analysis module and a feedback alarm module; The data acquisition module is used to collect the operation data of the mobile screening station to obtain corresponding screening data; The data processing module is used to process the obtained screening data to obtain a corresponding abnormal data set, wherein the abnormal data set includes an abnormal particle size data set and an abnormal amplitude data set; The data analysis module is used to perform fault analysis based on the received abnormal data set and generate corresponding fault diagnosis results; The feedback alarm module is used to issue corresponding visual alarms according to the fault diagnosis results.

2. A fault detection system for a mobile screening station according to claim 1, characterized in that: The process of the data acquisition module acquiring the screening data of the mobile screening station includes: The data acquisition module includes an image acquisition terminal, a weight data acquisition terminal and an amplitude data acquisition terminal, which are used to collect screening data of the mobile screening station. The screening data includes image information, weight data and amplitude data of the material at the discharge port of the screening station.

3. A fault detection system for a mobile screening station according to claim 2, characterized in that: The data processing module processes the obtained screening data to obtain an abnormal particle size data set, and the process includes: The contrast and brightness of the collected material image information are adjusted. After the adjustment is completed, the material and the background in the image are separated, and the features of the separated particles are extracted. The extracted features include the size and shape of the material. The particle size of the material is calculated based on the extracted features to obtain the particle size data of the corresponding material; According to the obtained particle size data, a corresponding particle size coefficient and a particle size average value are obtained, a particle size threshold is set according to the obtained particle size coefficient and the particle size average value, and the obtained particle size data is compared with the particle size threshold; If the particle size data is lower than the particle size threshold, the corresponding particle size data is marked as abnormal particle size data, and the marked abnormal particle size data is integrated to obtain a corresponding abnormal particle size data set.

4. A fault detection system for a mobile screening station according to claim 2, characterized in that: The data processing module processes the obtained screening data to obtain an abnormal amplitude data set, which includes: Reading the amplitude data in the screening data, and simultaneously obtaining the amplitude specification of the mobile screening station, traversing the received amplitude data, and comparing the amplitude data with the amplitude specification; If the amplitude data exceeds the amplitude specification, the corresponding amplitude data will be marked as abnormal amplitude data; All marked abnormal amplitude data are summarized to obtain an abnormal amplitude data set.

5. A fault detection system for a mobile screening station according to claim 3, characterized in that: The process of the data analysis module analyzing the acquired abnormal particle size data set includes: Read the obtained abnormal particle size data set to obtain the number of corresponding abnormal particle size data; Set a quantity threshold. If the number of abnormal particle size data is lower than the quantity threshold, it means that the mobile screening station is operating normally. If the number of abnormal particle size data is not less than the number threshold, the corresponding abnormal particle size data set is made into a data chart according to the collection time and identified; Obtain the peak point in the data chart, and determine whether there is a broken point in the screen of the mobile screening station based on it. If there is a broken point, generate corresponding damage information; if there is no broken point, generate corresponding blockage information; The abnormal particle size data are divided into several intervals, the number of abnormal particle size data in each interval is counted, and the number of obtained interval abnormal particle size data is compared with the number of total abnormal particle size data to obtain a corresponding number ratio; A particle size threshold is set. If the number ratio is higher than the particle size threshold, the corresponding screen is judged to have cracks or deformation, and wear information is generated.

6. A fault detection system for a mobile screening station according to claim 4, characterized in that: The process of the data analysis module analyzing the acquired abnormal amplitude data set includes: Set the fluctuation threshold, read the obtained abnormal amplitude data set, and obtain the corresponding amplitude fluctuation coefficient; If the amplitude fluctuation coefficient is not lower than the fluctuation threshold, the vibration equipment of the mobile screening station is judged to be faulty, and corresponding vibration equipment abnormality information is generated; If the amplitude fluctuation coefficient is lower than the fluctuation threshold, it is judged that the screen support of the mobile screening station is loose, and corresponding support abnormality information is generated.

7. A fault detection system for a mobile screening station according to claim 2, characterized in that: The process of the data analysis module analyzing the collected material weight data includes: Obtain the material weight data at the discharge port in the historical period, make a prediction based on the material weight data of the historical period and the material weight data collected in the current period, and obtain the predicted weight data of the material in the next period; A weight threshold range is set. If the predicted weight data is not within the weight threshold range, it is judged that the operation of the current mobile screening station is abnormal, and corresponding operation abnormality information is generated.

8. A fault detection system for a mobile screening station according to claim 1, characterized in that: The process of the feedback alarm module performing corresponding visual alarm according to the fault diagnosis result includes: When receiving blockage information or wear information, it is judged as a primary fault and a primary fault alarm is issued; When receiving the abnormal information of the bracket, it is judged as a secondary fault and a secondary fault alarm is issued; When abnormal information of vibration equipment is received, it is judged as a level 3 fault and a level 3 fault alarm is issued; When damage information or abnormal operation information is received, it is judged as a level 4 fault and a level 4 fault alarm is issued.

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