Equipment fault monitoring system based on digital twinning

Abstract

An equipment fault monitoring system based on digital twinning relates to the technical field of equipment monitoring and comprises a master control center which is in communication connection with a data acquisition module, a model construction module, a standard acquisition module, a first monitoring module, a yield acquisition module and a second monitoring module. The data acquisition module is used for acquiring and storing equipment information; the model construction module is used for constructing a digital twin model of industrial equipment; the standard acquisition module is used for acquiring a temperature standard, a pressure standard and a vibration standard; the first monitoring module is used for monitoring industrial equipment and judging whether the industrial equipment has a type of fault or not; the yield acquisition module is used for acquiring yield standards and yield adjustment change diagrams; the second monitoring module is used for judging whether the industrial equipment has second-class faults or not; according to the method, targeted standards can be formed for different industrial devices, and whether the industrial devices have faults in the aspect of production efficiency adjustment or not can be effectively judged.

Description

Technical Field

[0001] The present invention relates to the technical field of equipment monitoring, and specifically to a device fault monitoring system based on digital twin. Background Art

[0002] Device fault monitoring based on digital twin is an advanced method that combines real-time sensor data and virtual models, which can monitor the status of industrial equipment in real time and predict potential fault situations. By establishing a digital twin model for fault diagnosis and prediction of industrial equipment, it is possible to accurately judge whether there are faults in industrial equipment, which helps enterprises improve the reliability of industrial equipment, reduce maintenance costs, and minimize the risk of production interruption to the greatest extent; In the prior art, the fault monitoring of industrial equipment is mostly based on its physical conditions, which requires a preset reference standard. However, the reference standards in the prior art often fail to be adjusted accordingly with the usage conditions of industrial equipment. Moreover, in the prior art, although there is monitoring of the output of industrial equipment, there is a lack of monitoring of whether there are faults in the production efficiency adjustment of industrial equipment. In view of the deficiencies of the prior art, the present invention provides a device fault monitoring system based on digital twin. Summary of the Invention

[0003] The purpose of the present invention is to provide a device fault monitoring system based on digital twin.

[0004] The purpose of the present invention can be achieved through the following technical solutions: A device fault monitoring system based on digital twin, including a main control center, which is communicatively connected to a data acquisition module, a model construction module, a standard acquisition module, a first monitoring module, an output acquisition module, and a second monitoring module; The data acquisition module is used to collect and store the device information of industrial equipment; The model construction module is used to construct a digital twin model of industrial equipment according to the obtained device information; The standard acquisition module is used to obtain the temperature standard, pressure standard, and vibration standard of industrial equipment according to the digital twin model; The first monitoring module is used to monitor the temperature, pressure, and vibration frequency of industrial equipment and judge whether there are corresponding type I faults in the industrial equipment; The output acquisition module is used to obtain the output standard of industrial equipment and the corresponding output adjustment change diagram according to the digital twin model; The second monitoring module is used to judge whether there are corresponding type II faults in the industrial equipment according to the obtained output standard and output adjustment change diagram.

[0005] Further, the process of the data acquisition module collecting and storing the device information of industrial equipment includes: Set up a collection unit and a database. Collect the device information of industrial equipment through the collection unit. The device information includes the specification parameters, process parameters, historical data, environmental data, and maintenance data of industrial equipment. Review the collected device information through the main control center, and upload the device information that passes the review to the database for storage.

[0006] Further, the process of the model construction module constructing a digital twin model of industrial equipment based on the obtained device information includes: Set up a data processing unit. Perform data preprocessing on the obtained device information through the data processing unit to obtain corresponding available information. The data preprocessing includes: outlier processing, missing value processing, and normalization processing; Set up a model construction unit. Construct a physical model of industrial equipment based on the obtained specification parameters and process parameters through the model construction unit. Construct a behavior model of industrial equipment based on the obtained historical data, environmental data, and maintenance data. Integrate the constructed physical model and behavior model to obtain a digital twin model of industrial equipment.

[0007] Further, the process of the standard acquisition module obtaining the temperature standard, pressure standard, and vibration standard of industrial equipment based on the digital twin model includes: In the digital twin model, without changing the production efficiency of industrial equipment, but only changing its temperature, pressure, and vibration frequency, obtain the different outputs per unit time of industrial equipment at different temperatures, pressures, and vibration frequencies. Obtain the output change coefficient of industrial equipment based on the obtained different outputs; Set a change coefficient threshold. Compare the output change coefficient with the change coefficient threshold. Mark the output as normal state and abnormal state according to the comparison result. Take the temperature, pressure, and vibration frequency corresponding to the first output marked as abnormal state as the corresponding temperature standard, pressure standard, and vibration standard.

[0008] Further, the process of the first monitoring module monitoring the temperature, pressure, and vibration frequency of industrial equipment and judging whether there is a corresponding type of fault in the industrial equipment includes: Set up a temperature monitoring unit, a pressure monitoring unit, and a vibration monitoring unit. Obtain the monitored temperature, monitored pressure, and monitored vibration frequency of industrial equipment. Compare the monitored temperature, monitored pressure, and monitored vibration frequency with their corresponding standards. Judge whether there are temperature faults, pressure faults, and vibration faults in the industrial equipment according to the comparison result. The temperature faults, pressure faults, and vibration faults all belong to a type of fault. Generate corresponding type of alarm information according to the specific type of the type of fault, and feedback it to the staff.

[0009] Further, the process by which the output acquisition module obtains the output standard of industrial equipment according to the digital twin model includes: Taking the obtained monitored temperature, monitored pressure, and monitored vibration frequency as the monitoring conditions of industrial equipment, inputting the obtained monitoring conditions into all industrial equipment in the digital twin model, recording the output of each industrial equipment under these monitoring conditions, marking the obtained output as the monitored output, and obtaining the output standard of industrial equipment under the monitoring conditions based on the monitored outputs of all industrial equipment under the monitoring conditions.

[0010] Further, the process by which the output acquisition module obtains the output adjustment change diagram of industrial equipment according to the digital twin model includes: Obtaining the efficiency before adjustment and the efficiency after adjustment of industrial equipment in the digital twin model, monitoring the output of industrial equipment during the adjustment process to obtain the corresponding adjusted output, constructing an output adjustment change diagram based on the adjusted output, obtaining the output before adjustment and the output after adjustment of industrial equipment according to the output adjustment change diagram, and marking the time required for industrial equipment to change from the output before adjustment to the output after adjustment as the adjustment duration.

[0011] Further, the process by which the second monitoring module determines whether there are corresponding type-II faults in industrial equipment according to the obtained output standard and the output adjustment change diagram includes: Setting up an output monitoring unit, monitoring the output of industrial equipment through the output monitoring unit to obtain the corresponding actual output, comparing the monitored actual output with the obtained output standard, classifying the actual output into normal output and abnormal output according to the comparison result, and determining whether there is an output fault in industrial equipment, constructing an actual output change diagram based on the obtained actual output, and obtaining the actual duration of industrial equipment according to the actual output change diagram; Comparing the obtained adjustment duration with the actual duration, classifying the actual duration into normal duration and abnormal duration according to the comparison result, and determining whether there is an adjustment fault in the production efficiency adjustment of the industrial equipment. Both the output fault and the adjustment fault belong to type-II faults. Generating corresponding type-II alarm information according to the specific types of type-II faults and feeding it back to the staff.

[0012] Compared with the prior art, the beneficial effects of the present invention are: 1. By constructing a digital twin model of industrial equipment and obtaining various standards of industrial equipment according to the constructed digital twin model, the obtained various standards are the thresholds when the output of industrial equipment changes significantly. Through this method, it is possible to form targeted standards for different industrial equipment and even the same industrial equipment; 2. By monitoring the temperature, pressure, and vibration frequency of industrial equipment in reality and comparing the monitored data with their corresponding standards to determine whether there are faults in the industrial equipment, it is beneficial to improve the comprehensiveness of fault monitoring; 3. By obtaining the production adjustment change diagram and the actual production change diagram of the industrial equipment, and respectively obtaining the adjustment duration and the actual duration of the industrial equipment according to the two change diagrams, an effective judgment can be made on whether there are faults in the industrial equipment in terms of production efficiency adjustment based on the comparison result, which is beneficial to discovering the industrial equipment with adjustment faults and alarming it in time. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0014] As Figure 1 shown, a device fault monitoring system based on digital twin includes a main control center, and the main control center is communicatively connected to a data acquisition module, a model construction module, a standard acquisition module, a first monitoring module, a production acquisition module, and a second monitoring module; The data acquisition module is used to collect and store the device information of the industrial equipment; The model construction module is used to construct a digital twin model of the industrial equipment according to the obtained device information; The standard acquisition module is used to obtain the temperature standard, pressure standard, and vibration standard of the industrial equipment according to the digital twin model; The first monitoring module is used to monitor the temperature, pressure, and vibration frequency of the industrial equipment and determine whether there are corresponding type-I faults in the industrial equipment; The production acquisition module is used to obtain the production standard and the corresponding production adjustment change diagram of the industrial equipment according to the digital twin model; The second monitoring module is used to determine whether there are corresponding type-II faults in the industrial equipment according to the obtained production standard and the production adjustment change diagram.

[0015] It should be further noted that in the specific implementation process, the process of the data acquisition module collecting and storing the device information of the industrial equipment includes: Setting an acquisition unit and a database, collecting the device information of the industrial equipment through the acquisition unit, where the device information includes the specification parameters, process parameters, historical data, environmental data, and maintenance data of the industrial equipment, auditing the collected device information through the main control center, and uploading the device information passing the audit to the database for storage; The said specification parameters include, but are not limited to, the physical structure, component parts, technical specifications, etc. of industrial equipment. The process parameters include, but are not limited to, the speed of the production line, the rate of material input, process steps, etc. The historical data includes, but is not limited to, fault records, maintenance records, performance records, etc. The environmental data includes, but is not limited to, temperature, humidity, gas composition, etc. The maintenance data includes, but is not limited to, fault modes, occurrence time, maintenance measures and results, etc.

[0016] It should be further noted that, in the specific implementation process, the process of the model construction module constructing the digital twin model of industrial equipment based on the obtained equipment information includes: Set up a data processing unit, and through the data processing unit, perform data preprocessing on the obtained equipment information to obtain corresponding available information. The data preprocessing includes: outlier processing, missing value processing, and normalization processing; The outlier processing is used to clean abnormal equipment information. The outlier processing adopts the absolute median deviation outlier processing method. The missing value processing is used to fill in missing equipment information. The missing value processing adopts the statistic filling method. The normalization processing is used to unify the format of equipment information. The normalization processing adopts the Z-Score standardization method; Set up a model construction unit. Through the model construction unit, construct the physical model of industrial equipment based on the obtained specification parameters and process parameters, construct the behavior model of industrial equipment based on the obtained historical data, environmental data, and maintenance data, and integrate the constructed physical model and behavior model to obtain the digital twin model of industrial equipment.

[0017] It should be further noted that, in the specific implementation process, the process of the standard acquisition module obtaining the temperature standard, pressure standard, and vibration standard of industrial equipment based on the digital twin model includes: Taking the acquisition process of the temperature standard as an example, obtain the output per unit time of the industrial equipment at the first temperature T1 in the digital twin model, and mark the obtained output as the first output C1. The first temperature is the normal room temperature. Without changing the production efficiency of the industrial equipment and only changing its temperature, obtain the output per unit time of the industrial equipment at different temperatures; Gradually increase the temperature of the industrial equipment on the basis of the first temperature T1 to obtain the corresponding second temperature T2, third temperature T3, fourth temperature T4, fifth temperature T5,..., kth temperature T k , where the temperature increase each time is equal. Mark the outputs obtained by the industrial equipment at different temperatures as the second output C2, third output C3, fourth output C4, fifth output C5,..., kth output C k, obtain the production change coefficient of the industrial equipment, and mark the obtained production change coefficient as B;

[0018] Set the change coefficient threshold B0, compare the obtained production change coefficient with the set change coefficient threshold, and mark the production as normal state and abnormal state according to the comparison result. If B ≤ B0, mark it as the normal state; if B > B0, mark it as the abnormal state. Obtain the temperature corresponding to the first production marked as the abnormal state, and mark the obtained temperature as the temperature standard; Adopt the same method to obtain the production change coefficients of the industrial equipment under different pressures and different vibration frequencies respectively, compare the obtained production change coefficients with the set change coefficient threshold, and obtain the corresponding pressure standard and vibration standard according to the comparison result.

[0019] It should be further noted that in the specific implementation process, the process of the first monitoring module monitoring the temperature, pressure, and vibration frequency of the industrial equipment and judging whether there is a corresponding type of fault in the industrial equipment includes: In the embodiment of the present invention, taking the temperature of the industrial equipment as an example, a temperature monitoring unit is set inside the industrial equipment, and the temperature of the industrial equipment is monitored through the temperature monitoring unit to obtain the corresponding monitoring value. Set the monitoring period. When a monitoring period is reached, record the monitoring value obtained by the temperature monitoring unit, mark the recorded monitoring value as the monitoring temperature, and mark it as T j ; The present invention takes the fifth temperature T5 when obtaining the fifth production C5 as the temperature standard, compares the recorded monitoring temperature with the obtained temperature standard, and divides the monitoring temperature into normal temperature and abnormal temperature according to the comparison result. If T j ≤ T5, mark it as the normal temperature and judge that there is no temperature fault in the industrial equipment. If T j > T5, mark it as the abnormal temperature and judge that there is a temperature fault in the industrial equipment; And so on, adopt the same method to obtain the monitored pressure and monitored vibration frequency of the industrial equipment respectively, and compare them with the obtained pressure standard and vibration standard respectively to judge whether there are corresponding pressure faults and vibration faults in the industrial equipment. The temperature fault, pressure fault, and vibration fault all belong to the type of fault, and generate corresponding type of alarm information according to the specific type of the type of fault, and feedback it to the staff.

[0020] It should be further noted that in the specific implementation process, the process of the production acquisition module obtaining the production standard of the industrial equipment according to the digital twin model includes: In an embodiment of the present invention, taking any industrial device as an example, the monitored temperature, monitored pressure, and monitored vibration frequency of the industrial device are obtained, and the obtained monitored temperature, monitored pressure, and monitored vibration frequency are used as the monitoring conditions of the industrial device. In the digital twin model, the obtained monitoring conditions are input into all industrial devices, the output of each industrial device under these monitoring conditions is recorded, and the obtained output is marked as the monitored output; The obtained monitored outputs are numbered, denoted as i, where i = 1, 2, ……, n, and the obtained monitored outputs are marked as C ji , and according to the monitored outputs of all industrial devices under these monitoring conditions, the output standard of the industrial device under these monitoring conditions is obtained, and the obtained output standard is marked as C 标 ;

[0021] It should be further noted that in the specific implementation process, the process by which the output acquisition module obtains the output adjustment change diagram of the industrial device according to the digital twin model includes: Taking any industrial device as an example, in the digital twin model, the current production efficiency of the industrial device is marked as the pre-adjustment efficiency, and at the same time, the production efficiency of the industrial device after adjustment is marked as the post-adjustment efficiency. The output during the adjustment process of the industrial device is monitored to obtain the corresponding adjusted output. The adjusted output includes both the output of the industrial device under the pre-adjustment efficiency and the output of the industrial device under the post-adjustment efficiency, as well as the output of the industrial device during the adjustment process; According to the obtained adjusted output, an output adjustment change diagram with time as the abscissa and adjusted output as the ordinate is constructed. According to the output adjustment change diagram, the outputs of the industrial device under the pre-adjustment efficiency and the post-adjustment efficiency are obtained, and the two obtained outputs are respectively marked as the pre-adjustment output and the post-adjustment output. The time required for the industrial device to change from the pre-adjustment output to the post-adjustment output is marked as the adjustment duration.

[0022] It should be further noted that in the specific implementation process, the process by which the second monitoring module determines whether there are corresponding type-II faults in the industrial device according to the obtained output standard and the output adjustment change diagram includes: Taking any industrial device as an example, a production output monitoring unit is set inside the industrial device. The output of the industrial device is monitored through the production output monitoring unit to obtain the corresponding actual output, and the obtained actual output is marked as C s , the monitored actual output is compared with the obtained output standard, and according to the comparison result, the actual output is divided into normal output and abnormal output. If C s < C 标, it is marked as abnormal production, and it is determined that there is a production fault in the industrial equipment. If C s ≥C 标 , it is marked as normal production, and it is determined that there is no production fault in the industrial equipment; Construct a graph of actual production volume change with time on the abscissa and actual production volume on the ordinate based on the obtained actual production volume. Use the same method to obtain the production volume of the industrial equipment under the efficiency before adjustment and after adjustment according to the graph of actual production volume change, and mark the two obtained production volumes as the actual production volume before and the actual production volume after respectively. Mark the time required for the industrial equipment to change from the actual production volume before to the actual production volume after as the actual duration; Mark the obtained adjustment duration and actual duration as S 调 and S 实 , and compare the two. Divide the actual duration into normal duration and abnormal duration according to the comparison result. If S 实 <S 调 , it is marked as normal duration, and it is determined that there is no adjustment fault in the production efficiency adjustment of the industrial equipment. If S 实 ≥S 调 , it is marked as abnormal duration, and it is determined that there is an adjustment fault in the production efficiency adjustment of the industrial equipment. The production fault and the adjustment fault both belong to the second-class faults, and corresponding second-class alarm information is generated according to the specific types of the second-class faults and fed back to the staff.

[0023] 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 digital twin-based equipment fault monitoring system, including a main control center, characterized in that: The main control center is communicatively connected with a data acquisition module, a model building module, a standard acquisition module, a first monitoring module, a yield acquisition module, and a second monitoring module; The data acquisition module is used to collect and store equipment information of industrial equipment; The model building module is used to build a digital twin model of industrial equipment based on the acquired equipment information; The standard acquisition module is used to obtain the temperature standard, pressure standard, and vibration standard of industrial equipment according to the digital twin model; The first monitoring module is used to monitor the temperature, pressure and vibration frequency of the industrial equipment and determine whether the industrial equipment has a corresponding type of fault; The output acquisition module is used to obtain the output standard of industrial equipment and the corresponding output adjustment change diagram according to the digital twin model; The second monitoring module is used to determine whether the industrial equipment has a corresponding second type of fault based on the obtained production standard and the production adjustment change diagram.

2. According to claim 1, a digital twin-based equipment fault monitoring system is characterized in that: The process of the data acquisition module collecting and storing the equipment information of the industrial equipment includes: A collection unit and a database are provided, and the equipment information of the industrial equipment is collected by the collection unit, and the collected equipment information is uploaded to the database for storage.

3. According to claim 2, a digital twin-based equipment fault monitoring system is characterized in that: The process of the model building module building a digital twin model of industrial equipment according to the acquired equipment information includes: Setting a data processing unit, through which the acquired device information is preprocessed to obtain corresponding usable information, wherein the data preprocessing includes: outlier processing, missing value processing, and normalization processing; A model building unit is provided, and a physical model and a behavioral model of the industrial equipment are built by the model building unit, and the built physical model and the behavioral model are integrated to obtain a digital twin model of the industrial equipment.

4. The device fault monitoring system based on digital twin according to claim 3 is characterized in that: The process of the standard acquisition module obtaining the temperature standard, pressure standard, and vibration standard of industrial equipment according to the digital twin model includes: In the digital twin model, the production efficiency of the industrial equipment is not changed, and only the temperature, pressure, and vibration frequency are changed to obtain the different outputs of the industrial equipment per unit time at different temperatures, pressures, and vibration frequencies. The output change coefficient of the industrial equipment is obtained based on the different outputs obtained. Set a variation coefficient threshold, compare the output variation coefficient with the variation coefficient threshold, mark the output as normal or abnormal based on the comparison result, and use the temperature, pressure, and vibration frequency corresponding to the first output marked as abnormal as the corresponding temperature standard, pressure standard, and vibration standard.

5. The device fault monitoring system based on digital twin according to claim 4 is characterized in that: The process in which the first monitoring module monitors the temperature, pressure, and vibration frequency of the industrial equipment and determines whether the industrial equipment has a corresponding type of fault includes: A temperature monitoring unit, a pressure monitoring unit, and a vibration monitoring unit are set up to obtain the monitoring temperature, monitoring pressure, and monitoring vibration frequency of the industrial equipment, and the monitoring temperature, monitoring pressure, and monitoring vibration frequency are compared with their corresponding standards. According to the comparison results, it is determined whether the industrial equipment has a temperature fault, a pressure fault, or a vibration fault. The temperature fault, pressure fault, and vibration fault all belong to a class of faults. According to the specific type of a class of faults, a corresponding class of alarm information is generated and fed back to the staff.

6. The device fault monitoring system based on digital twin according to claim 5 is characterized in that: The process of the output acquisition module obtaining the output standard of industrial equipment according to the digital twin model includes: The obtained monitored temperature, monitored pressure, and monitored vibration frequency are used as monitoring conditions. In the digital twin model, the monitored output of all industrial equipment is obtained according to the monitoring conditions, and the output standard of the industrial equipment under the monitoring conditions is obtained based on the monitored output.

7. The device fault monitoring system based on digital twin according to claim 6 is characterized in that: The process of the output acquisition module obtaining the output adjustment change diagram of industrial equipment according to the digital twin model includes: The pre-adjustment efficiency and post-adjustment efficiency of the industrial equipment are obtained in the digital twin model, the output of the industrial equipment during the adjustment process is monitored to obtain the corresponding adjusted output, an output adjustment change graph is constructed based on the adjusted output, the pre-adjustment output and post-adjustment output of the industrial equipment are obtained based on the output adjustment change graph, and the time required for the industrial equipment to transform from the pre-adjustment output to the post-adjustment output is marked as the adjustment duration.

8. The device fault monitoring system based on digital twin according to claim 7 is characterized in that: The process of the second monitoring module judging whether the industrial equipment has a corresponding second type of fault according to the obtained production standard and the production adjustment change diagram includes: Setting a production monitoring unit to obtain the actual production of industrial equipment, comparing the actual production with the production standard, and judging whether the industrial equipment has a production failure according to the comparison result; constructing an actual production change graph according to the actual production, and obtaining the corresponding actual duration according to the actual production change graph; The obtained adjustment time is compared with the actual time, and the comparison result is used to determine whether there is an adjustment failure in the production efficiency adjustment of the industrial equipment. The production failure and adjustment failure both belong to Class II failures. According to the specific type of Class II failure, corresponding Class II alarm information is generated and fed back to the staff.

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