Heating furnace fault diagnosis system

Abstract

The invention relates to the technical field of heating furnaces, and discloses a heating furnace fault diagnosis system which is composed of a data acquisition and processing module, a data center module, an analysis and diagnosis module, a user interaction module, a communication module and an equipment management and configuration module. The master database and the slave database are arranged in the system, the master database is responsible for processing all data under the normal condition, and the slave database serves as a backup. When the master database breaks down, the slave database can automatically take over and continue to provide services, it is ensured that even if the master database breaks down, the system can still operate normally, so that the system is prevented from being paralyzed due to the faults of the databases, and real-time data synchronization is kept between the master database and the slave database; by continuously synchronizing the data of the master database to the slave database, the data consistency between the master database and the slave database is ensured, and the beneficial effects that redundancy is achieved, and system paralysis cannot be caused by damage of constituent parts are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of heating furnaces, and in particular to a heating furnace fault diagnosis system. Background Art

[0002] With the advent of the Industrial 4.0 era, the application of industrial information technology is becoming more and more comprehensive. From the data collection of the most basic equipment and the application of centralized monitoring technology to the current intelligent analysis, risk identification and evaluation, the technology guiding production management is gradually applied to various industrial production. In the oilfield heating furnace industry, although the heating furnace automation control technology has been widely used, it is currently only in the extensive combustion control stage, that is, it only focuses on the safety of the burner and the temperature indicators required for production. For the energy-saving technology of the heating furnace, the technology to improve the furnace efficiency, and the safety risk management technology of the heating furnace, the failure of the heating furnace is the most fundamental cause of safety accidents. How to ensure the safe operation of the heating furnace is a problem that needs to be solved urgently.

[0003] In order to solve the defects of the prior art, a heating furnace fault diagnosis system with a publication number of CN 108897268 A was found through searching, which includes: power supply unit, programmable logic controller, network switching unit, optical fiber transceiver, power distribution wiring unit, human-computer interaction unit; the diagnosis system includes: data acquisition service unit, data center, dispatch center, database, Web service interface; the client includes: input device unit, communication unit, logic control unit, centralized monitoring unit, fault diagnosis unit, equipment management unit, basic configuration unit. Compared with the prior art, through the application of automatic control technology, computer software technology, and network communication technology, real-time monitoring of the heating furnace is realized, so as to make timely judgment on the fault of the heating furnace, make the equipment of the heating furnace safer, and improve the safety of the heating furnace.

[0004] However, the programmable logic editor and fiber optic transceiver in the aforementioned technical solution are too irreplaceable and lack redundant design. Once the two are damaged, the reliability of the system will be affected. At the same time, although the system includes data acquisition and data centers, there is no specific description in the manual on how to effectively manage and analyze these data, and how to convert these data into useful information and warnings. Summary of the invention

[0005] Technical issues solved:

[0006] In view of the deficiencies in the prior art, the present invention provides a heating furnace fault diagnosis system, which has the advantages of system redundancy and will not be paralyzed due to damage to components, and can effectively convert collected data into effective information and analyze the information for early warning, thereby solving the above technical problems.

[0007] Technical solution:

[0008] To achieve the above object, the present invention provides the following technical solutions: a heating furnace fault diagnosis system, the diagnosis system is composed of a data acquisition and processing module, a data center module, an analysis and diagnosis module, a user interaction module, a communication module, and an equipment management and configuration module;

[0009] The data acquisition and processing module is composed of a data acquisition unit, a data buffer unit and a data processing unit. The data acquisition unit is used to collect the operation data of the heating furnace in real time, including temperature, pressure and flow rate; the data buffer unit is used to cache data to prevent loss; the data processing unit is used to perform preliminary processing and formatting on the collected data;

[0010] The data center module includes a master database and a slave database. The data center module is used to centrally store and process data. When the master database fails, the slave database provides services.

[0011] The analysis and diagnosis module is used to process and analyze the collected data in real time, and to set up multiple data analysis engine instances to ensure that the analysis task is not affected by a single engine failure;

[0012] The user interaction module is used to display the status, fault information and warning of the heating furnace in real time;

[0013] The communication module is used to exchange data with the control system, data center and client;

[0014] The device management and configuration module manages the configuration, status and maintenance records of the device;

[0015] The main database in the data center module is D main , from the database D standby ,Under normal conditions, the primary database handles all data requests, while the secondary database acts as a backup, providing services when the primary database fails;

[0016] The normal working state expression of the data center module is:

[0017] R=D main

[0018] The database response service R is provided by the primary database D main Provided, the main database handles all data requests;

[0019] Failover state expression:

[0020] R=D standby When D main When a failure occurs

[0021] When the primary database D main When a failure occurs,standby Automatically take over and provide services to ensure service continuity.

[0022] Preferably, the data synchronization relationship expression in the data center module is:

[0023] D standby =f(D main )

[0024] Among them: Main database D main and from database D standby The data is kept synchronized between the slave database and the master database. Function f represents the synchronization process to ensure data consistency between the slave database and the master database.

[0025] Preferably, the data acquisition expression in the data acquisition and processing module is:

[0026] D acq ={T,P,F}

[0027] Among them: data acquisition unit D acq Responsible for real-time collection of heating furnace operation data, where T represents temperature, P represents pressure, and F represents flow rate;

[0028] The data buffer expression is:

[0029] D buffer =Buffer(D acq )

[0030] Where: Data buffer unit D buffer Responsible for caching data to prevent loss. Function Buffer(·) represents the collection of data D acq Stored in buffer.

[0031] Preferably, the data acquisition and processing module also includes data processing calculation, and the data processing expression is:

[0032] D proc =Process(D buffer

[0033] Among them: Data processing unit D proc Responsible for cached data D buffer Perform preliminary processing and formatting. The function Process(·) represents data processing and formatting operations.

[0034] Preferably, the analysis and diagnosis module is expressed as:

[0035] Data Analysis:

[0036] A diag =Analyze(D proc )

[0037] Among them: Analysis and diagnosis module A diag For the processed data D proc Perform real-time processing and analysis. The function Analyze represents the analysis operation.

[0038] The data analysis engine expression is:

[0039] A engines ={E 1 ,E 2 ,…,E n}

[0040] Set up multiple data analysis engine instances A engines , where E i represents the i-th data analysis engine, and n represents the total number of engines. These engines work in parallel to ensure that the analysis task is not affected by the failure of a single engine.

[0041] Preferably, the analysis task allocation expression in the analysis and diagnosis module is:

[0042] T i =Distribute(D proc ,E i )

[0043] Among them: Distribute the processed data to each data analysis engine E i , the function Distribute represents the data distribution operation, T i Represents the analysis task assigned to the i-th engine.

[0044] Preferably, the user interaction module expression is:

[0045] Status display:

[0046] U state =Display(S)

[0047] Among them: User interaction module U state It is used to display the state S of the heating furnace in real time. The function Display represents the display operation;

[0048] Fault information display:

[0049] U fault =Display(F info )

[0050] Among them: When the heating furnace fails, the user interaction module U fault To display fault information F info .

[0051] Preferably, the user interaction module further includes a warning display calculation, and the warning display expression is:

[0052] U warning =Display(W info

[0053] Among them: User interaction module U warning Also used to display warning information W info , to alert users to potential problems.

[0054] Preferably, the data exchange expression between the user interaction module and the control system is:

[0055] C ctrl =Communicate(D ctrl )

[0056] Among them: Communication module C ctrl Responsible for data exchange with the control system, where D ctrl Represents the data between the control system and the Communicate function, which indicates the data exchange operation;

[0057] The data exchange expression with the data center is:

[0058] C data =Communicate(D data )

[0059] Among them: Communication module C data Responsible for data exchange with the data center, where D data Represents data between data centers.

[0060] Preferably, the device configuration management expression in the device management and configuration module is:

[0061] M config =ManageConfig(D config

[0062] Among them: Equipment management and configuration module M config Responsible for the configuration management of the equipment, including D config Represents the data of device configuration. The function ManageConfig represents the operation of managing configuration.

[0063] Compared with the prior art, the present invention provides a heating furnace fault diagnosis system, which has the following beneficial effects:

[0064] 1. The present invention provides a master database and a slave database in the system. The master database is responsible for all data processing under normal circumstances, while the slave database serves as a backup. When the master database fails, the slave database will automatically take over and continue to provide services, ensuring that even if there is a problem with the master database, the system can still operate normally, thereby preventing the system from being paralyzed due to database failure. The master database and the slave database maintain real-time data synchronization, and the data consistency between the two is ensured by continuously synchronizing the data of the master database to the slave database. The synchronization mechanism can quickly switch to the slave database when the master database fails, avoiding data loss or inconsistency problems, and further enhancing the stability of the system. The system has built-in multiple data analysis engine instances, which work in parallel. Even if one of the engines fails, other engines can continue to perform data analysis. The analysis function of the system will not be interrupted due to the failure of a single engine, ensuring the continuity of the analysis and diagnosis tasks, and achieving the beneficial effect of having redundancy and not causing system paralysis due to damage to the components.

[0065] 2. The present invention is responsible for real-time collection of the operation data of the heating furnace, including key parameters such as temperature, pressure, and flow rate, through the data acquisition and processing module. The collected raw data is subsequently temporarily stored by the data buffer unit to prevent loss, and is finally preliminarily processed and formatted by the data processing unit to better perform subsequent analysis. The data center module centrally stores the processed data to ensure data security and facilitate subsequent analysis. In addition, the data synchronization mechanism between the master database and the slave database ensures the consistency of data updates and also provides data recovery guarantees for the system when the master database fails. The analysis and diagnosis module receives the processed data and performs real-time analysis. The system sets up multiple data analysis engine instances so that the analysis task is not affected by the failure of a single engine. By allocating data analysis tasks to different engines, when one engine fails, the remaining engines can still continue the analysis task, ensuring the continuity and effectiveness of the analysis process, and achieving the beneficial effect of effectively converting the collected data into effective information and analyzing the information for early warning. BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Figure 1 It is a schematic diagram of the system of the present invention; DETAILED DESCRIPTION

[0067] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0068] See also Figure 1 , a heating furnace fault diagnosis system, the diagnosis system is composed of a data acquisition and processing module, a data center module, an analysis and diagnosis module, a user interaction module, a communication module, and an equipment management and configuration module;

[0069] The data acquisition and processing module is composed of a data acquisition unit, a data buffer unit and a data processing unit. The data acquisition unit is used to collect the operation data of the heating furnace in real time, including temperature, pressure and flow rate; the data buffer unit is used to cache data to prevent loss; the data processing unit is used to perform preliminary processing and formatting on the collected data;

[0070] The data center module includes a master database and a slave database. The data center module is used to centrally store and process data. When the master database fails, the slave database provides services.

[0071] The analysis and diagnosis module is used to process and analyze the collected data in real time, and to set up multiple data analysis engine instances to ensure that the analysis task is not affected by a single engine failure;

[0072] The user interaction module is used to display the status, fault information and warning of the heating furnace in real time;

[0073] The communication module is used to exchange data with the control system, data center and client;

[0074] The device management and configuration module manages the configuration, status and maintenance records of the device;

[0075] The main database in the data center module is D main , from the database D standby ,Under normal conditions, the primary database handles all data requests, while the secondary database acts as a backup, providing services when the primary database fails;

[0076] The normal working state expression of the data center module is:

[0077] R=D main

[0078] The database response service R is provided by the primary database D main Provided, the main database handles all data requests;

[0079] Failover state expression:

[0080] R=D standby When D main When a failure occurs

[0081] When the primary database D main When a failure occurs,standby Automatically take over and provide services to ensure service continuity.

[0082] The system has a master database and a slave database. The master database is responsible for all data processing under normal circumstances, while the slave database serves as a backup. When the master database fails, the slave database automatically takes over and continues to provide services. This design ensures that the system can still operate normally even if there is a problem with the master database, thereby preventing the system from being paralyzed by database failure.

[0083] The master database and the slave database maintain real-time data synchronization. By continuously synchronizing the data of the master database to the slave database, the data consistency between the two is ensured. This synchronization mechanism can quickly switch to the slave database when the master database fails, avoiding data loss or inconsistency, and further enhancing the stability of the system.

[0084] The system has multiple data analysis engine instances built in, and these engines work in parallel. Even if one of the engines fails, the other engines can continue to analyze the data. In this way, the system's analysis function will not be interrupted by the failure of a single engine, ensuring the continuity of analysis and diagnosis tasks.

[0085] The processed data is distributed to different data analysis engines. If an engine fails, the task can be reallocated to other engines that are working normally. This mechanism avoids the interruption of the overall analysis task due to the failure of a single engine and ensures the stability of the system analysis function.

[0086] The communication module is responsible for data exchange with the control system, data center and client. The modular communication design allows different communication links to operate independently. If a communication link fails, other links can continue to work, thus ensuring that the communication between the system and the outside world is not affected, enhancing the overall reliability of the system.

[0087] The device management and configuration module manages the configuration, status and maintenance records of the device. Through real-time monitoring of the device status and management of maintenance records, the system can adjust the device configuration in a timely manner and respond quickly to device failures. This management mechanism helps prevent device failures from affecting the overall function of the system and improves the stability of the system.

[0088] The data acquisition and processing module is responsible for real-time acquisition of the operation data of the heating furnace, including key parameters such as temperature, pressure, flow rate, etc. The collected raw data is subsequently temporarily stored by the data buffer unit to prevent loss, and is ultimately processed and formatted by the data processing unit for better subsequent analysis.

[0089] The data center module centrally stores processed data to ensure data security and facilitate subsequent analysis. In addition, the data synchronization mechanism between the master database and the slave database ensures the consistency of data updates and also provides data recovery guarantee for the system when the master database fails.

[0090] The analysis and diagnosis module receives the processed data and performs real-time analysis. The system sets up multiple data analysis engine instances so that the analysis task is not affected by the failure of a single engine. By assigning data analysis tasks to different engines, when one engine fails, the remaining engines can still continue the analysis task, ensuring the continuity and effectiveness of the analysis process.

[0091] The user interaction module is responsible for displaying the analyzed information to the user in a timely manner. It can not only display the status and fault information of the heating furnace, but also display early warning information. Through timely early warning, users can take measures in advance to avoid the occurrence of faults or reduce the impact of faults.

[0092] The communication module is a bridge between the system and external communication, ensuring data exchange between the system and the control system, data center and client. With the assistance of the communication module, the external system can receive the operating status and fault warning information of the heating furnace in real time, so as to respond and process in time.

[0093] The device management and configuration module configures the device, manages the status and organizes the maintenance records. Through effective device management strategies, potential problems of the device can be discovered in time and maintenance can be carried out in advance to reduce the possibility of device failure. At the same time, when a device failure occurs, the problem can be quickly located and handled.

[0094] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A heating furnace fault diagnosis system, characterized in that: The diagnostic system consists of a data acquisition and processing module, a data center module, an analysis and diagnosis module, a user interaction module, a communication module, and a device management and configuration module; The data acquisition and processing module is composed of a data acquisition unit, a data buffer unit and a data processing unit. The data acquisition unit is used to collect the operation data of the heating furnace in real time, including temperature, pressure and flow rate; the data buffer unit is used to cache data to prevent loss; the data processing unit is used to perform preliminary processing and formatting on the collected data; The data center module includes a master database and a slave database. The data center module is used to centrally store and process data. When the master database fails, the slave database provides services. The analysis and diagnosis module is used to process and analyze the collected data in real time, and to set up multiple data analysis engine instances to ensure that the analysis task is not affected by a single engine failure; The user interaction module is used to display the status, fault information and warning of the heating furnace in real time; The communication module is used to exchange data with the control system, data center and client; The device management and configuration module manages the configuration, status and maintenance records of the device; The main database in the data center module is D main , from the database D standby ,Under normal conditions, the primary database handles all data requests, while the secondary database acts as a backup, providing services when the primary database fails; The normal working state expression of the data center module is: R=D main The database response service R is provided by the primary database D main Provided, the main database handles all data requests; Failover state expression: R=D standby When D main When a failure occurs When the primary database D main When a failure occurs, standby Automatically take over and provide services to ensure service continuity.

2. A heating furnace fault diagnosis system according to claim 1, characterized in that: The data synchronization relationship expression in the data center module is: D standby =f(D main ) Among them: Main database D main and from database D standby The data is kept synchronized between the slave database and the master database. Function f represents the synchronization process to ensure data consistency between the slave database and the master database.

3. A heating furnace fault diagnosis system according to claim 2, characterized in that: The data acquisition expression in the data acquisition and processing module is: D acq ={T,P,F} Among them: data acquisition unit D acq Responsible for real-time collection of heating furnace operation data, where T represents temperature, P represents pressure, and F represents flow rate; The data buffer expression is: D buffer =Buffer(D acq ) Where: Data buffer unit D buffer Responsible for caching data to prevent loss. Function Buffer(·) represents the collection of data D acq Stored in buffer.

4. A heating furnace fault diagnosis system according to claim 3, characterized in that: The data acquisition and processing module also includes data processing calculations, and the data processing expression is: D proc =Process(D buffer ) Among them: Data processing unit D proc Responsible for cached data D buffer Perform preliminary processing and formatting. The function Process(·) represents data processing and formatting operations.

5. A heating furnace fault diagnosis system according to claim 3, characterized in that: The analysis and diagnosis module expression is: Data Analysis: A diag =Analyze(D proc ) Among them: Analysis and diagnosis module A diag For the processed data D proc Perform real-time processing and analysis. The function Analyze represents the analysis operation. The data analysis engine expression is: A engines }{E1,E2,…,E n } Set up multiple data analysis engine instances A engines , where E i represents the i-th data analysis engine, and n represents the total number of engines. These engines work in parallel to ensure that the analysis task is not affected by the failure of a single engine.

6. A heating furnace fault diagnosis system according to claim 5, characterized in that: The analysis task allocation expression in the analysis and diagnosis module is: T i =Distribute(D proc ,E i ) Among them: Distribute the processed data to each data analysis engine E i , the function Distribute represents the data distribution operation, T i Represents the analysis task assigned to the i-th engine.

7. A heating furnace fault diagnosis system according to claim 1, characterized in that: The user interaction module expression is: Status display: U state =Display(S) Among them: User interaction module U state It is used to display the state S of the heating furnace in real time. The function Display represents the display operation; Fault information display: U fault =Display(F info ) Among them: When the heating furnace fails, the user interaction module U fault To display fault information F info .

8. A heating furnace fault diagnosis system according to claim 1, characterized in that: The user interaction module also includes an early warning display calculation, and the early warning display expression is: U warning =Display(W info ) Among them: User interaction module U warning Also used to display warning information W info , to alert users to potential problems.

9. A heating furnace fault diagnosis system according to claim 1, characterized in that: The data exchange expression between the user interaction module and the control system is: C ctrl =Communicate(D ctrl ) Among them: Communication module C ctrl Responsible for data exchange with the control system, where D ctrl Represents the data between the control system and the Communicate function, which indicates the data exchange operation; The data exchange expression with the data center is: C data =Communicate(D data ) Among them: Communication module C data Responsible for data exchange with the data center, where D data Represents data between data centers.

10. A heating furnace fault diagnosis system according to claim 1, characterized in that: The device configuration management expression in the device management and configuration module is: M config =ManageConfig(D config ) Among them: Equipment management and configuration module M config Responsible for the configuration management of the equipment, including D config Represents the data of device configuration. The function ManageConfig represents the operation of managing configuration.

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