Remote online mechanical equipment health monitoring and operation and maintenance system based on APP

Abstract

The invention discloses a remote online mechanical equipment health monitoring and operation and maintenance system based on an APP, relates to the technical field of equipment health monitoring, and solves the technical problem that in the prior art, influence factors irrelevant to mechanical equipment are not excluded, so that the judgment result of the health state of the mechanical equipment is inaccurate. Equipment data and operation state parameters of mechanical equipment are collected through a sensor, a vibration amplitude diagram is obtained by recording vibration time corresponding to vibration and combining the vibration, and a vibration state is obtained by comparing fluctuation duration in the vibration amplitude diagram with a preset fluctuation duration threshold value; combining the sound wave health state, the temperature health state and the vibration state to obtain an equipment health state; and counting abnormal sound wave times, abnormal temperature times and fault vibration times in the equipment health state, calculating to obtain an equipment performance value in combination with a set sound wave proportionality coefficient, a set temperature proportionality coefficient and a set vibration proportionality coefficient, and generating a corresponding maintenance suggestion based on the equipment performance condition.

Description

Technical Field

[0001] The present invention belongs to the field of equipment health monitoring, involves Internet of Things technology, and specifically is a remote online mechanical equipment health monitoring and operation and maintenance system based on an APP. Background Art

[0002] In the manufacturing and industrial fields, the demand for improving production efficiency is increasing day by day. As an indispensable key in the manufacturing and industrial fields, the health status of mechanical equipment directly affects production efficiency, product quality, and enterprise competitiveness. The failure of mechanical equipment will cause the production line to stop, affect the execution of the production plan, and increase production costs. When the equipment fails and then is repaired, this method not only increases the downtime but also may cause greater losses. In addition, the cost of emergency repair is usually higher than that of preventive maintenance; being able to analyze the health status of the equipment in real-time, online, and conveniently can greatly reduce the cost required for maintenance.

[0003] The invention patent with the application number CN2023112374029 discloses a modular rolling mill health status monitoring system. This invention collects equipment data of the rolling mill through pressure sensors, resolver sensors, and vibration sensors, analyzes the rotation trajectory and vibration frequency through the equipment data, and predicts the service life of the rolling mill; when analyzing the vibration frequency, this method detects abnormal frequencies in the vibration signal and uses vibration analysis to predict the remaining service life; the abnormal frequency vibrations generated by mechanical equipment during operation may be due to imbalances, looseness, or other problems in the mechanical equipment, resulting in changes in vibration characteristics. However, when the mechanical equipment has a short-term normal vibration frequency change due to power supply imbalance or other factors, abnormal frequency vibrations will also occur. This kind of abnormal frequency vibration belongs to other factors or normal frequency changes and has nothing to do with the reasons of the mechanical equipment itself. If not excluded, it will affect the judgment result of the health status of the mechanical equipment.

[0004] The present invention provides a remote online mechanical equipment health monitoring and operation and maintenance system based on an APP to solve the above technical problems. Summary of the Invention

[0005] The present invention aims to solve at least one of the technical problems existing in the prior art; for this purpose, the present invention proposes a remote online mechanical equipment health monitoring and operation and maintenance system based on an APP, which is used to solve the technical problem that the judgment result of the health status of mechanical equipment is inaccurate due to the failure to exclude influencing factors unrelated to the mechanical equipment in the prior art.

[0006] To achieve the above object, the first aspect of the present invention provides a remote online mechanical equipment health monitoring and operation and maintenance system based on an APP, including: a data collection module, a status monitoring module, and a user interaction module;

[0007] Data collection module: used to collect equipment data and operating status parameters of mechanical equipment through sensors;

[0008] Status monitoring module: used to obtain the equipment health status based on the operating status parameters, and evaluate the equipment based on the equipment health status and equipment data to obtain the equipment performance status;

[0009] User interaction module: used to generate corresponding maintenance suggestions based on the equipment performance status, and set up an interaction interface for users to query equipment data and operating status parameters.

[0010] Preferably, obtaining the equipment health status according to the operating status parameters includes:

[0011] A1: Extract the operating status parameters; among them, the operating status parameters include ultrasonic waves, vibration, and regional temperature of the mechanical equipment;

[0012] A2: Extract the fault sound wave frequency, corresponding fault type, and regional temperature threshold from the database;

[0013] A3: Determine whether the ultrasonic wave matches the fault sound wave frequency; if so, mark the ultrasonic wave status of the corresponding equipment as abnormal sound wave, and combine the corresponding fault type and ultrasonic wave status to obtain the sound wave health status; if not, mark the ultrasonic wave status of the corresponding equipment as normal sound wave;

[0014] A4: Determine whether the regional temperature is greater than the regional temperature threshold; if so, jump to A5; if not, continue to detect the regional temperature;

[0015] A5: Determine whether the regional temperature is in a continuous increasing trend; if so, mark the temperature status of the corresponding area as abnormal temperature, and combine the corresponding area and the corresponding temperature status to obtain the temperature health status; if not, mark the corresponding area as a high-temperature area;

[0016] A6: Perform spectrum analysis on the vibration of the mechanical equipment to obtain the vibration status;

[0017] A7: Integrate the sound wave health status, temperature health status, and vibration status to obtain the equipment health status.

[0018] Preferably, performing spectrum analysis on the vibration of the mechanical equipment to obtain the vibration status includes:

[0019] Extract the vibration of the mechanical equipment;

[0020] Record the vibration time corresponding to the vibration, and combine the vibrations according to the continuous vibration time to obtain a vibration amplitude diagram; count the vibration fluctuation range where fluctuations occur in the vibration amplitude diagram, and mark the duration of the vibration fluctuation range as the fluctuation duration;

[0021] Set the fluctuation duration threshold; determine whether the fluctuation duration of the vibration fluctuation range is greater than the fluctuation duration threshold; if yes, mark the corresponding vibration state as a faulty vibration; if not, mark the corresponding vibration state as a normal vibration; wherein, the fluctuation duration threshold is set according to the small vibration fluctuation range in the vibration amplitude diagram.

[0022] Preferably, setting the fluctuation duration threshold according to the small vibration fluctuation range in the vibration amplitude diagram includes:

[0023] Statistically analyze the fluctuation duration of all vibration fluctuation ranges in the vibration amplitude diagram;

[0024] Mark the time when the vibration fluctuation range starts to fluctuate as Ti, and statistically analyze the mode of [T(i + 1) - Ti] and mark it as the time difference mode; where i represents the number of the vibration fluctuation range;

[0025] Mark [T(i + 1) - Ti] as the fluctuation time difference of the i-th vibration fluctuation range, mark the vibration fluctuation range with the same fluctuation time difference as the time difference mode as the abnormal fluctuation range, eliminate the abnormal fluctuation range to obtain the updated vibration fluctuation range; statistically analyze the mode of the fluctuation duration in the updated vibration fluctuation range to obtain the fluctuation duration threshold.

[0026] Preferably, evaluating the device based on the device health status and device data to obtain the device performance status includes:

[0027] Extract the device health status and device data; wherein, the device data includes the used years and the designed life of the mechanical equipment;

[0028] Statistically analyze the number of abnormal sound waves, the number of abnormal temperatures, and the number of faulty vibrations in the device health status respectively; set the sound wave ratio coefficient, the temperature ratio coefficient, and the vibration ratio coefficient; wherein, the sound wave ratio coefficient, the temperature ratio coefficient, and the vibration ratio coefficient are set according to the influence degrees of sound waves, temperature, and faults on the normal operation of the device, and the sum of the sound wave ratio coefficient, the temperature ratio coefficient, and the vibration ratio coefficient is equal to 1;

[0029] Calculate the product of the sum of the product of the number of abnormal sound waves and the sound wave ratio coefficient, the product of the number of abnormal temperatures and the temperature ratio coefficient, and the product of the number of faulty vibrations and the vibration ratio coefficient and the ratio of the used years to the designed life to obtain the device performance value;

[0030] Combine the device health status and the device performance value to obtain the device performance status.

[0031] Preferably, generating the corresponding maintenance suggestions based on the device performance status includes:

[0032] Set a usage performance threshold; wherein, the usage performance threshold is based on the maximum equipment performance value of this type of mechanical equipment without affecting production safety and product quality;

[0033] Determine whether the equipment performance value is greater than the performance threshold; if yes, mark the corresponding mechanical equipment as a faulty equipment; if no, mark the corresponding mechanical equipment as a normal equipment;

[0034] For faulty equipment, generate maintenance suggestions for replacement and repair; for normal equipment, generate maintenance suggestions for regular maintenance.

[0035] Compared with the prior art, the beneficial effects of the present invention are:

[0036] 1. The present invention collects equipment data and operating state parameters of mechanical equipment through sensors, and obtains the equipment health status based on the comparison results of the operating state parameters with the fault sound wave frequencies, corresponding fault types, and regional temperature thresholds in the database, which can predict potential fault risks, make maintenance work more targeted, and thus improve the overall reliability of the equipment; count the number of abnormal sound waves, abnormal temperature times, and fault vibration times in the equipment health status, and calculate the equipment performance value by combining the set sound wave proportional coefficient, temperature proportional coefficient, and vibration proportional coefficient. Generating corresponding maintenance suggestions based on the equipment performance status can significantly reduce the risk of safety accidents caused by equipment failures, reduce unnecessary maintenance activities, lower maintenance costs, help enterprises better comply with industry standards and safety regulations, and ensure the equipment operates in a safe state.

[0037] 2. The present invention records the vibration time corresponding to the vibration and combines the vibrations to obtain a vibration amplitude diagram, sets a fluctuation duration threshold according to the small vibration fluctuation range in the vibration amplitude diagram, and compares the fluctuation duration in the vibration amplitude diagram with the preset fluctuation duration threshold to obtain the vibration state, which can analyze the vibration characteristics of the equipment in more detail, identify subtle vibration changes, and improve the accuracy of fault diagnosis. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0039] Figure 1 It is a flowchart of the work process of an embodiment of the present invention.

[0040] Figure 2 It is a system composition diagram of the present invention.

[0041] Figure 3 This is the complete flowchart for obtaining the health status of the device in an embodiment of the present invention. Detailed implementation manners

[0042] The technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.

[0043] Please refer to Figures 1 - 3 , an embodiment of the first aspect of the present invention provides a remote online mechanical equipment health monitoring and operation and maintenance system based on an APP, including: a data collection module, a status monitoring module, and a user interaction module;

[0044] The data collection module: is used to collect the device data and operation status parameters of the mechanical equipment through sensors.

[0045] Exemplarily, the ultrasonic waves, the temperature of each region, and the vibration frequency of each region of the mechanical equipment are collected through a temperature sensor, an acoustic wave sensor, and a vibration sensor; in this embodiment, the mechanical equipment has been in use for 3 years and the involved lifespan is 5 years.

[0046] The status monitoring module: is used to obtain the device health status according to the operation status parameters, and evaluate the device based on the device health status and device data to obtain the device performance status.

[0047] Exemplarily, the fault acoustic wave frequency of this type of mechanical equipment and the corresponding fault type are extracted from the database, as well as the regional temperature threshold of each region of the mechanical equipment under normal operation. It is judged whether the ultrasonic wave band of the mechanical equipment contains a band identical to the fault acoustic wave frequency. In this embodiment, it is judged that the ultrasonic wave band of the current mechanical equipment contains a band identical to the fault acoustic wave frequency when a crack occurs. The ultrasonic wave state of the mechanical equipment is marked as an abnormal acoustic wave, and the combination of the fault type of crack occurrence and the ultrasonic wave state of abnormal acoustic wave is used to obtain the acoustic wave health status; it is judged whether the regional temperature of each region on the mechanical equipment is greater than the corresponding regional temperature threshold. In this embodiment, after comparison, it is obtained that the regional temperatures of two regions are greater than the corresponding regional temperature thresholds. It is then judged whether the regional temperatures of these two regions are in a continuous growth trend. It is judged that the regional temperature of Region 1 is not in a continuous growth trend, and the regional temperature of Region 2 is in a continuous growth trend. The temperature state of Region 2 is marked as an abnormal temperature, and the combination of Region 2 and the temperature state of abnormal temperature is used to obtain the temperature health status, and Region 1 is marked as a high-temperature region.

[0048] It should be noted that when mechanical components experience problems such as wear and cracks, ultrasonic signals within a specific frequency range will be generated. By matching the ultrasonic frequency band of the mechanical equipment with the frequency of the fault sound wave, the wear, cracks, and other faults of the mechanical equipment can be accurately judged.

[0049] Record the vibration time corresponding to the vibration frequency in the mechanical equipment, and combine them to obtain a continuous vibration amplitude diagram with the vibration time on the abscissa and the vibration frequency on the ordinate. Statistically analyze the vibration fluctuation range where fluctuations occur in the vibration amplitude diagram, and mark the duration of the vibration fluctuation range as the fluctuation duration. In this embodiment, a total of 5 groups of vibration fluctuation ranges are obtained.

[0050] Statistically analyze the fluctuation duration of all vibration fluctuation ranges in the vibration amplitude diagram, number the vibration fluctuation ranges in chronological order, mark the time when the fluctuation starts in the vibration fluctuation range as Ti, calculate T2 - T1, T3 - T2, T4 - T3, T5 - T4 to obtain four groups of time differences. T3 - T2 and T4 - T3 are the same. Select T3 - T2 as the mode of the time difference, and mark the vibration fluctuation ranges corresponding to T3 and T4 as abnormal fluctuation ranges. The abnormal fluctuation range of the iron ball obtains an updated vibration fluctuation range, and the updated vibration fluctuation range includes T1, T2, and T5; statistically analyze the mode of the fluctuation duration among them to obtain the fluctuation duration threshold.

[0051] Judge whether the fluctuation duration of the vibration fluctuation range is greater than the fluctuation duration threshold; in this embodiment, it is obtained that the fluctuation duration of the vibration fluctuation range corresponding to T2 is greater than the fluctuation duration threshold, and the fluctuation durations of the vibration fluctuation ranges corresponding to T1 and T5 are less than the fluctuation duration threshold. Mark the vibration state corresponding to T2 as fault vibration, and mark the vibration fluctuation ranges corresponding to T1 and T5 as normal vibration.

[0052] In some other preferred embodiments, if after obtaining the updated vibration fluctuation range, when calculating the fluctuation duration threshold, there is no mode in the fluctuation duration within the updated vibration fluctuation range, then calculate the average of all updated vibration fluctuation ranges as the fluctuation duration threshold.

[0053] Statistically analyze the number of abnormal sound waves, the number of abnormal temperatures, and the number of fault vibrations in the equipment health status; in this embodiment, the sound wave proportionality coefficient is set to 0.3, the temperature proportionality coefficient is set to 0.3, and the vibration proportionality coefficient is set to 0.4; calculate the equipment performance value SBX = 1.6 through the formula SBX=(SBC×SBX + WDC×WDX + ZDC×ZDX)×YSN / SJN; where, SBC represents the number of abnormal sound waves, SBX represents the sound wave proportionality coefficient, WDC represents the number of abnormal temperatures, WDX represents the temperature proportionality coefficient, ZDC represents the number of fault vibrations, ZDX represents the vibration proportionality coefficient, YSN represents the number of years of use, and SJN represents the design life.

[0054] User Interaction Module: It is used to generate corresponding maintenance suggestions based on the device performance status and set an interaction interface for users to query device data and operating status parameters.

[0055] Exemplarily, in this embodiment, the performance threshold for use is set to 1.5; it is judged whether the device performance value is greater than the performance threshold. It is judged that the device performance value is greater than the performance threshold, indicating that the performance of the mechanical equipment no longer meets the normal use specifications and needs to be repaired or replaced to ensure production safety and product quality; a user interaction page is designed, and users can query the device data, device performance status and maintenance suggestions of the mechanical equipment on the user interaction page.

[0056] It should be noted that the larger the device performance value, the more fault occurrences there are when the mechanical equipment is running. Therefore, a performance threshold for use is set. If the device performance value is greater than the performance threshold for use, it indicates that the mechanical equipment is no longer suitable for continued operation and production.

[0057] Some of the data in the above formula are taken as numerical values after removing the dimension. The formula is obtained by software simulation of a large amount of collected data to get a formula closest to the actual situation; the preset parameters and preset thresholds in the formula are set by those skilled in the art according to the actual situation or obtained through simulation of a large amount of data.

[0058] The working principle of the present invention:

[0059] The present invention collects device data and operating status parameters of mechanical equipment through sensors, compares the operating status parameters with the fault sound wave frequencies, corresponding fault types and regional temperature thresholds in the database, records the vibration time corresponding to the vibration and combines the vibrations to obtain a vibration amplitude diagram, sets a fluctuation duration threshold according to the small vibration fluctuation range in the vibration amplitude diagram, and compares the fluctuation duration in the vibration amplitude diagram with the preset fluctuation duration threshold to obtain the vibration status; combines the sound wave health status, temperature health status and vibration status to obtain the device health status, counts the number of abnormal sound waves, abnormal temperature times and fault vibration times in the device health status, and calculates the device performance value by combining the set sound wave proportional coefficient, temperature proportional coefficient and vibration proportional coefficient, and generates corresponding maintenance suggestions based on the device performance status.

[0060] The above embodiments are only used to illustrate the technical method of the present invention and not to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical method of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the technical method of the present invention.

Claims

1. A remote online mechanical equipment health monitoring and operation and maintenance system based on APP, characterized in that: include: Data collection module, status monitoring module and user interaction module; Data collection module: used to collect equipment data and operating status parameters of mechanical equipment through sensors; Status monitoring module: used to obtain the health status of the equipment according to the operating status parameters, and evaluate the equipment based on the health status and equipment data to obtain the equipment performance status; User interaction module: used to generate corresponding maintenance suggestions based on equipment performance status, and set up an interactive interface for users to query equipment data and operating status parameters.

2. According to the APP-based remote online mechanical equipment health monitoring and operation and maintenance system of claim 1, it is characterized in that: The obtaining of the health status of the device according to the operating status parameters includes: A1: Extract operating status parameters; the operating status parameters include ultrasonic wave, vibration and regional temperature of mechanical equipment; A2: Extract the fault sound wave frequency, corresponding fault type and regional temperature threshold from the database; A3: Determine whether the ultrasonic wave matches the fault sound wave frequency; if yes, mark the ultrasonic state of the corresponding device as abnormal sound wave, and combine the corresponding fault type with the ultrasonic state to obtain the sound wave health state; if no, mark the ultrasonic state of the corresponding device as normal sound wave; A4: Determine whether the regional temperature is greater than the regional temperature threshold; if yes, jump to A5; if no, continue to detect the corresponding regional temperature; A5: Determine whether the regional temperature is in a continuous growth trend; if yes, mark the temperature state of the corresponding region as abnormal temperature, and combine the corresponding region and the corresponding temperature state to obtain the temperature health state; if no, mark the corresponding region as a high temperature region; A6: Perform spectrum analysis on the vibration of mechanical equipment to obtain the vibration status; A7: The sound wave health status, temperature health status and vibration status are integrated to obtain the equipment health status.

3. According to claim 2, the remote online mechanical equipment health monitoring and operation and maintenance system based on APP is characterized in that: The step of performing spectrum analysis on the vibration of the mechanical equipment to obtain the vibration state includes: Extract vibrations from mechanical equipment; Record the vibration time corresponding to the vibration, and combine the vibrations according to the continuous vibration time to obtain a vibration amplitude graph; count the vibration fluctuation range in the vibration amplitude graph, and mark the duration of the vibration fluctuation range as the fluctuation duration; Set a fluctuation duration threshold; determine whether the fluctuation duration of the vibration fluctuation range is greater than the fluctuation duration threshold; if yes, mark the corresponding vibration state as fault vibration; if no, mark the corresponding vibration state as normal vibration; wherein the fluctuation duration threshold is set according to the small vibration fluctuation range in the vibration amplitude diagram.

4. According to claim 3, the remote online mechanical equipment health monitoring and operation and maintenance system based on APP is characterized in that: The fluctuation duration threshold is set according to the small vibration fluctuation range in the vibration amplitude diagram, including: Count the fluctuation duration of all vibration fluctuation ranges in the vibration amplitude graph; The time of the first fluctuation in the vibration fluctuation range is marked as Ti, and the mode of [T(i+1)-Ti] is counted and marked as the time difference mode; wherein i represents the number of the vibration fluctuation range; Mark [T(i+1)-Ti] as the fluctuation time difference of the i-th vibration fluctuation range, mark the vibration fluctuation range with the same fluctuation time difference and time difference mode as the abnormal fluctuation range, eliminate the abnormal fluctuation range to obtain the updated vibration fluctuation range; count the mode of fluctuation duration in the updated vibration fluctuation range to obtain the fluctuation duration threshold.

5. According to the APP-based remote online mechanical equipment health monitoring and operation and maintenance system of claim 1, it is characterized in that: The step of evaluating the device based on the device health status and device data to obtain the device performance status includes: Extract equipment health status and equipment data; equipment data includes the service life and design life of mechanical equipment; The number of abnormal sound waves, the number of abnormal temperatures and the number of fault vibrations in the health status of the equipment are counted respectively; the sound wave proportional coefficient, the temperature proportional coefficient and the vibration proportional coefficient are set; wherein the sound wave proportional coefficient, the temperature proportional coefficient and the vibration proportional coefficient are set according to the influence of the sound wave, the temperature and the fault on the normal operation of the equipment, and the sum of the sound wave proportional coefficient, the temperature proportional coefficient and the vibration proportional coefficient is equal to 1; The equipment performance value is calculated by multiplying the sum of the product of the number of abnormal sound waves and the sound wave proportional coefficient, the product of the number of abnormal temperature and the temperature proportional coefficient, the product of the number of fault vibrations and the vibration proportional coefficient, and the ratio of the service life to the design life; The device health status is combined with the device performance value to obtain the device performance status.

6. The APP-based remote online mechanical equipment health monitoring and operation and maintenance system according to claim 1 is characterized in that: Generating corresponding maintenance suggestions based on equipment performance conditions includes: Set a performance threshold; the performance threshold is based on the maximum equipment performance value of the type of mechanical equipment while ensuring that production safety and product quality are not affected; Determine whether the equipment performance value is greater than the performance threshold; if yes, mark the corresponding mechanical equipment as a faulty equipment; if no, mark the corresponding mechanical equipment as a normal equipment; For faulty equipment, maintenance recommendations are generated for replacement and repair; for normal equipment, maintenance recommendations are generated for frequent maintenance.

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