Motor-oriented wireless state monitoring and maintenance system

Abstract

The invention discloses a motor-oriented wireless state monitoring and maintenance system, which comprises a main control module, an oil injection module and a data acquisition module which are arranged on a motor end cover, and is characterized in that the main control module is respectively connected with the oil injection module and the data acquisition module; the oil injection module receives and executes an external instruction and outputs real-time liquid level information at the same time. The data acquisition module acquires parameter information of the motor and outputs the parameter information; the main control module issues the external instruction, receives and processes the real-time liquid level information and the parameter information, and judges whether an alarm signal is sent out or not and whether a next instruction signal is sent out or not according to a set threshold value and a period condition; wherein the threshold value comprises a vibration threshold value and a temperature threshold value.

Description

Technical Field

[0001] The invention relates to the technical field of motor monitoring, and in particular to a wireless state monitoring and maintenance system for motors. Background Art

[0002] At present, industrial motors play an important role in the fields of processing, manufacturing, and chemical industry. Most motors will stop production due to mechanical failures, and may even cause safety accidents, causing huge economic losses to enterprises and threatening people's lives and property safety. These devices currently require manual maintenance and inspection, which is costly and difficult to find problems during manual maintenance, posing hidden dangers;

[0003] In response to the above problems, there are many patents on motor operating condition protection. The motor status monitoring is achieved through one or more combinations of motor operating status parameter information. It needs to be independently installed on the outside of the motor. The structure of some monitoring devices is too complicated, which will bring difficulties to the actual installation and use on site. The monitoring device needs to be powered independently, which requires independent wiring. Most factories now have high-voltage equipment, and the laying of external power supply lines is relatively cumbersome. If battery-powered power is used, the power life is short, and the unstable voltage affects the use of the equipment. In addition, some existing monitoring inventions are not rigidly connected to the motor. The monitoring device will collect environmental information, affecting the monitoring precision and accuracy. Summary of the invention

[0004] In view of the defects in the prior art, the purpose of the present invention is to provide a motor wireless status monitoring and maintenance system for users to query data and issue early warning signals for faults, and to realize automatic oiling of the motor, so that the motor can operate more safely and stably.

[0005] The present invention provides a wireless condition monitoring and maintenance system for a motor, comprising:

[0006] A power generation module, a main control module, an oil injection module and a data acquisition module are arranged on the motor end cover, the main control module is connected to the oil injection module, the data acquisition module and the power generation module respectively, and the power generation module supplies power to the main control module;

[0007] The oil injection module receives and executes external instructions, and outputs real-time liquid level information; the data acquisition module collects and outputs parameter information of the motor;

[0008] The main control module issues the external command, receives and processes the real-time liquid level information and the parameter information, and determines whether to issue an alarm signal and whether to issue the next command signal according to the set threshold value and periodic conditions;

[0009] The thresholds include a temperature threshold and a vibration threshold.

[0010] Preferably, the oil filling module comprises: an oil box, an execution unit and a liquid level detection unit, wherein the execution unit and the liquid level detection unit are arranged inside the oil box;

[0011] The execution unit is used to receive the instruction and add lubricant to the motor; the liquid level detection unit is used to detect the liquid level of the lubricant in the oil box and send the liquid level information to the main control module.

[0012] Preferably, the parameter information includes vibration parameters and temperature parameters, and the data acquisition module includes a temperature acquisition unit and a vibration acquisition unit;

[0013] The vibration collection unit is used to collect the vibration parameters and transmit them to the main control module; the temperature collection unit is used to collect the temperature parameters.

[0014] Preferably, the vibration acquisition unit acquires the vibration parameters in three directions of X, Y and Z through an acceleration sensor, and the temperature acquisition unit acquires the temperature parameters through a temperature sensor.

[0015] Preferably, the vibration parameters include one or more combinations of vibration frequency, effective value of velocity, acceleration value, displacement, and effective value of pulse factor.

[0016] Preferably, the main control module includes a control unit, a data processing unit and a display unit.

[0017] The display unit is used to display the parameter information, the liquid level information and the alarm signal; the data processing unit is used to process, analyze and judge the parameter information and the liquid level information, and output an alarm signal or a command signal; the control unit is used to receive the command signal and execute it.

[0018] Preferably, the vibration acquisition unit collects the vibration acceleration through the acceleration sensor and outputs it as an electrical signal, and then the data processing unit converts the electrical signal into a digital signal, and obtains the velocity V=Aωsin(ωt+90°) and the displacement d=Asin(ωt) by integration, wherein A is the collected vibration acceleration, and outputs the envelope acceleration value, envelope peak value, envelope effective value, displacement peak-to-peak value, velocity effective value and other data, and finally obtains the trend graph, waveform graph, spectrum graph, envelope graph, inverse spectrum graph and other graphic data through the acceleration vibration measurement algorithm; skewness, kurtosis, margin and other characteristic values;

[0019] When the characteristic value is greater than the vibration threshold, the main control module outputs an alarm signal;

[0020] The data processing unit compares the temperature parameter with the temperature threshold, and when the temperature parameter is greater than the temperature threshold, the main control module outputs an alarm signal.

[0021] Preferably, it further comprises a communication module, wherein the communication module connects the main control module and an external host computer and is used for sending the instruction to the main control module and transmitting the parameter information and the liquid level information to the host computer.

[0022] Preferably, a rectifier module is further included, wherein the rectifier module is connected to the main control module and is used to adjust the alternating current generated by the motor into direct current and transmit the direct current to the main control module.

[0023] Preferably, the rectifier module comprises: a rectifier circuit, a filter circuit, and a step-down circuit;

[0024] The rectifier circuit is used to convert the AC signal into a DC signal; the filter circuit filters the DC signal; the reduction circuit is used to reduce the high voltage to a lower voltage level.

[0025] Compared with the prior art, the present invention has at least the following beneficial effects: the present invention is rigidly connected to the motor, which improves the reliability of the monitoring system and the monitoring accuracy. The traditional motor monitoring solution is to install sensors on the motor housing or motor base to realize temperature and vibration monitoring. Since the vibration energy is transmitted through the housing, it will be attenuated, thus affecting the measurement accuracy. The connection between the monitoring system and the terminal is realized through wireless long-distance communication. There is no need for personnel to inspect the equipment on site, and there is no need to lay wires at the work site, which reduces the construction difficulty and maintenance costs. The signal receiving device can be installed in the electric control box to directly view the motor operation status at the terminal. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0027] Figure 1 A schematic diagram of a system according to an embodiment of the present invention;

[0028] Figure 2 This is a workflow diagram of the oil injection process according to an embodiment of the present invention;

[0029] Figure 3 The following is a flowchart of a data acquisition module according to an embodiment of the present invention.

[0030] Figure 4 is a system schematic diagram of another embodiment of the present invention;

[0031] Figure 5A cable signal table of an acceleration sensor according to an embodiment of the present invention. DETAILED DESCRIPTION

[0032] A more detailed description of a wireless condition monitoring and maintenance system for a motor of the present invention will be provided below in conjunction with a schematic diagram, wherein a preferred embodiment of the present invention is shown, and it should be understood that those skilled in the art may modify the present invention described herein while still achieving the advantageous effects of the present invention. Therefore, the following description should be understood as being widely known to those skilled in the art and not as a limitation of the present invention.

[0033] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0034] The present invention is described in more detail in the following paragraphs by way of example with reference to the accompanying drawings. The advantages and features of the present invention will become more apparent from the following description. It should be noted that the accompanying drawings are in very simplified form and are not in exact proportions, and are only used to facilitate and clearly assist in illustrating the purpose of the embodiments of the present invention.

[0035] This embodiment provides a wireless condition monitoring and maintenance system for a motor, including:

[0036] A power generation module, a main control module, an oil injection module and a data acquisition module are arranged on the motor end cover, wherein the main control module is respectively connected to the oil injection module, the data acquisition module and the power generation module, and the power generation module supplies power to the main control module.

[0037] The oil injection module receives and executes external instructions, and outputs real-time liquid level information. The data acquisition module acquires and outputs parameter information of the motor.

[0038] The main control module sends the external command, receives and processes the real-time liquid level information and the parameter information, and determines whether to send out an alarm signal and whether to send out the next command signal according to the set threshold value and periodic conditions.

[0039] The thresholds include a temperature threshold and a vibration threshold.

[0040] For details, please refer to Figure 1, which is a system schematic diagram of this embodiment. In this embodiment, the power generation module, the main control module, the oil injection module and the data acquisition module are arranged on the motor end cover, and the end cover is rigidly connected to the motor rotor.

[0041] After the motor starts, the rotor in the power generation module rotates to supply power to the main control module, and the main control module starts working. At this time, the user can issue an instruction to oil the motor. After receiving the oil injection instruction, the main control module sends it to the oil injection module, which executes the instruction and feeds back the real-time liquid level information. At this time, the data acquisition module also collects the parameter information of the motor and sends it to the main control module. The main control module is equipped with judgment conditions to judge and analyze the real-time liquid level information and parameter information to see whether the motor is in normal working condition and whether the next oil injection instruction needs to be executed.

[0042] In this embodiment, the external command is sent to the main control module via the host computer. Preferably, the host computer can be a computer, a mobile phone, a tablet, a panel, a touch screen and a series of other products, and this application does not limit the host computer.

[0043] Furthermore, the oil filling module includes: an oil box, an execution unit and a liquid level detection unit, and the execution unit and the liquid level detection unit are arranged inside the oil box.

[0044] The execution unit is used to receive the instruction and add lubricant to the motor. The liquid level detection unit is used to detect the liquid level of the lubricant in the oil box and send the liquid level information to the main control module.

[0045] For details, please refer to Figure 2 When the host computer sends the oil injection command, it is sent to the main control module. The main control module sends the command to the oil injection module. The execution unit of the oil injection module works to add lubricant to the motor main bearing. At the same time, the liquid level in the oil box decreases. The liquid level detection unit detects the real-time liquid level information and sends the information to the main control module. At the same time, the main control module displays the liquid level information and sends the liquid level information to the host computer.

[0046] Furthermore, the parameter information collected by the data collection module includes vibration parameters and temperature parameters, and the data collection module includes a temperature collection unit and a vibration collection unit.

[0047] The vibration acquisition unit is used to collect the vibration parameters of the motor and transmit them to the main control module. The temperature acquisition unit is used to collect temperature parameters. Specifically, the vibration acquisition unit collects vibration parameters in three directions through an acceleration sensor, and the vibration parameters include one or more combinations of vibration frequency, velocity effective value, acceleration value, displacement, and pulse factor effective value. The temperature acquisition unit collects temperature parameters through a temperature sensor.

[0048] Furthermore, the main control module includes a control unit, a data processing unit and a display unit.

[0049] The display unit is used to display the parameter information, the liquid level information and the alarm signal. The data processing unit is used to process and analyze the parameter information and the liquid level information, and output an alarm signal or a command signal. The control unit is used to receive the command signal and execute it.

[0050] For details, please refer to Figure 3 The data acquisition module is composed of a temperature acquisition unit and a vibration acquisition unit, wherein the vibration unit collects one or more combinations of vibration frequency, velocity effective value, acceleration value, displacement, and pulse factor effective value. The vibration unit collects the vibration acceleration through the acceleration sensor to output the acceleration electrical signal, and then converts the electrical signal into a digital signal through the main control module. The velocity and displacement information are obtained through the integral formula V = Aωsin(ωt+90°) and d = Asin(ωt), where A is the collected vibration acceleration data. After integration, the envelope acceleration value, envelope peak value, envelope effective value, displacement peak-to-peak value, velocity effective value and other data are output, and finally the trend chart, waveform chart, spectrum chart, envelope chart, inverse spectrum chart and other graphic data and skewness, kurtosis, margin and other characteristic values ​​are obtained through the algorithm. The MEMS accelerometer is used inside the acceleration sensor, which can convert the physical vibration signal into an analog electrical signal. The analog electrical signal is connected to the main control module after passing through the filter and conditioning circuit. Through analog-to-digital conversion, the velocity, acceleration, intensity and original waveform of the vibration signal are obtained and uploaded.

[0051] In this embodiment, reference Figure 5 For vibration parameters, the data acquisition module outputs the vibration parameters in the three directions of X, Y, and Z to the main control module. After integration, the main control module uses the algorithm to obtain the total value trend chart. The total value trend chart is a waveform chart obtained by connecting the X, Y, and Z axis velocity values ​​and temperature values ​​collected by the acceleration sensor according to the numerical values. The waveform chart reflects the relationship between the amplitude collected by the acceleration sensor and the time and frequency. In the data processing unit of the main control module, the corresponding frequency domain characteristics and time domain characteristic values ​​are obtained through Fourier transform. When the characteristic value is greater than the vibration threshold, the algorithm outputs an alarm message, and the host computer displays the alarm message.

[0052] For example, when the motor rotor is unbalanced, the time domain waveform is similar to the standard sine wave and has a large amplitude. The radial vibration is large and the axial vibration is small on the spectrum, and the axis motion trajectory is elliptical. When the rotor is misaligned, 2 to 3 peaks appear in each cycle of the time domain characteristic value, and a large 2-fold frequency component appears in the frequency domain characteristic. The 2-fold frequency component measured in the horizontal and vertical directions in the radial direction increases at the same time, and the axis motion trajectory is banana-shaped. When mechanical looseness occurs, the time domain waveform is not easy to judge the mechanical looseness fault. The 3 to 10-fold frequency component of the frequency domain characteristic is very large, and the vibration amplitude of the radial spectrum is greater than the axial vibration amplitude.

[0053] For temperature parameters, the temperature sensor collects temperature data and outputs a digital signal. The main control module receives the temperature digital signal and compares it with the set temperature threshold. If the set temperature threshold is exceeded, an alarm is issued. Preferably, the temperature signal is collected using a DS18B20 chip, which can output a digital signal. The temperature signal can be directly obtained through the main control chip, and the main control module uploads the signal.

[0054] For the liquid level information, the system structure is designed with an oil float. Combined with the designed reed switch circuit, the reed switches at different positions will be closed according to the different liquid levels, thereby controlling the total resistance value in the loop. The voltage of the resistor is collected by the ADC of the main control. By calculating the voltage, the oil height at this time can be determined. The upper computer sends the oil injection action command, which is sent to the oil injection module through the main control module. The oil injection module receives the command and starts the oil injection action. The motor driver chip is used in the system circuit, the motor control pin is enabled, and the output of the motor driver chip is controlled through the IO pin to control the rotation of the motor. At the same time, the system can have counting logic, by judging whether the time interval and number of data transmissions reach the set time interval oil injection cycle, that is, the cycle condition, so as to achieve regular lubrication of the system.

[0055] In this embodiment, the periodic conditions are set to the monthly oil injection amount and the monthly oil injection number n. The oil injection action is completed n times within the time. Forced oil injection can also be selected, and the system will immediately perform the oil injection action and add 1.8 ml of oil.

[0056] The vibration threshold is divided into four categories: A, B, C, and D, and the four categories are further divided into one, two

[0057] The three-level threshold value is used to set the equipment alarm. Class A is 0.71mm / s, 1.8mm / s, and 4.5mm / s; Class B is 1.12mm / s, 2.8mm / s, and 7.1mm / s; Class C is 1.8mm / s, 4.5mm / s, and 11.2mm / s; and Class D is 2.8mm / s, 7.1mm / s, and 18mm / s. It also supports the setting of custom vibration alarm thresholds, and adjusts the vibration thresholds according to the actual use of the site. The temperature thresholds are different due to the different equipment site environments and different equipment working conditions, resulting in different equipment heating conditions. Therefore, the temperature thresholds need to be set according to the equipment conditions on site. When the temperature or vibration exceeds the threshold of the equipment, the main control module outputs an alarm signal.

[0058] Please refer to Figure 4 , further, it also includes a communication module, which connects the main control module with an external host computer and is used to send the command to the main control module and transmit the parameter information and the liquid level information to the host computer.

[0059] Furthermore, it also includes a rectifier module, which is connected to the main control module and is used to adjust the alternating current generated by the motor into direct current and transmit the direct current to the main control module.

[0060] Furthermore, the rectifier module includes: a rectifier circuit, a filter circuit, and a step-down circuit;

[0061] The rectifier circuit is used to convert an AC signal into a DC signal; the filter circuit filters the DC signal; and the reduction circuit is used to reduce a high voltage to a lower voltage level.

[0062] The above specific examples are used to illustrate the present invention, which is only used to help understand the present invention and is not intended to limit the present invention. For those skilled in the art, according to the concept of the present invention, some simple deductions, modifications or substitutions can be made.

Claims

1. A wireless condition monitoring and maintenance system for motors. It is characterized in that include: A power generation module, a main control module, an oil injection module and a data acquisition module are arranged on the motor end cover, the main control module is connected to the oil injection module, the data acquisition module and the power generation module respectively, and the power generation module supplies power to the main control module; The oil injection module receives and executes external instructions, and outputs real-time liquid level information; the data acquisition module collects and outputs parameter information of the motor; The main control module issues the external command, receives and processes the real-time liquid level information and the parameter information, and determines whether to issue an alarm signal and whether to issue the next command signal according to the set threshold value and periodic conditions; The thresholds include a vibration threshold and a temperature threshold.

2. The wireless condition monitoring and maintenance system for electric motors as claimed in claim 1, It is characterized in that The oil filling module comprises: an oil box, an execution unit and a liquid level detection unit, wherein the execution unit and the liquid level detection unit are arranged inside the oil box; The execution unit is used to receive the instruction and add lubricant to the motor; the liquid level detection unit is used to detect the liquid level of the lubricant in the oil box and send the liquid level information to the main control module.

3. The wireless condition monitoring and maintenance system for electric motors as claimed in claim 2, It is characterized in that The parameter information includes vibration parameters and temperature parameters, and the data acquisition module includes a temperature acquisition unit and a vibration acquisition unit; The vibration collection unit is used to collect the vibration parameters and transmit them to the main control module; the temperature collection unit is used to collect the temperature parameters.

4. The wireless condition monitoring and maintenance system for electric motors as claimed in claim 3, It is characterized in that The vibration acquisition unit acquires the vibration parameters in three directions of X, Y and Z through an acceleration sensor, and the temperature acquisition unit acquires the temperature parameter through a temperature sensor.

5. The wireless condition monitoring and maintenance system for electric motors as claimed in claim 4, It is characterized in that The vibration parameters include one or more combinations of vibration frequency, velocity effective value, acceleration value, displacement, and pulse factor effective value.

6. The wireless condition monitoring and maintenance system for electric motors as claimed in claim 3, It is characterized in that The main control module includes a control unit, a data processing unit and a display unit. The display unit is used to display the parameter information, the liquid level information and the alarm signal; the data processing unit is used to process, analyze and judge the parameter information and the liquid level information, and output an alarm signal or a command signal; the control unit is used to receive the command signal and execute it.

7. The wireless condition monitoring and maintenance system for electric motors as claimed in claim 6, It is characterized in that The vibration acquisition unit collects the vibration acceleration through the acceleration sensor and outputs it as an electrical signal, and then converts the electrical signal into a digital signal through the data processing unit, and obtains the velocity V=Aωsin(ωt+90°) and the displacement d=Asin(ωt) by integration, where A is the collected vibration acceleration, and outputs the envelope acceleration value, envelope peak value, envelope effective value, displacement peak-to-peak value, velocity effective value and other data, and finally obtains the trend graph, waveform graph, spectrum graph, envelope graph, inverse spectrum graph and other graphic data through the acceleration vibration measurement algorithm; skewness, kurtosis, margin and other characteristic values; When the characteristic value is greater than the vibration threshold, the main control module outputs an alarm signal; The data processing unit compares the temperature parameter with the temperature threshold, and when the temperature parameter is greater than the temperature threshold, the main control module outputs an alarm signal.

8. The wireless condition monitoring and maintenance system for electric motors as claimed in claim 1, It is characterized in that It also includes a communication module, which connects the main control module and an external host computer and is used to send the command to the main control module and transmit the parameter information and the liquid level information to the host computer.

9. The wireless condition monitoring and maintenance system for electric motors as claimed in claim 1, It is characterized in that It also includes a rectifier module, which is connected to the main control module and is used to adjust the alternating current generated by the motor into direct current and transmit the direct current to the main control module.

10. The wireless condition monitoring and maintenance system for electric motors as claimed in claim 9, It is characterized in that The rectifier module includes: a rectifier circuit, a filter circuit, and a step-down circuit; The rectifier circuit is used to convert an AC signal into a DC signal; the filter circuit filters the DC signal; and the reduction circuit is used to reduce a high voltage to a lower voltage level.

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