Vibration equipment monitoring system

Abstract

The invention relates to a vibration equipment monitoring system, and belongs to the field of vibration equipment. The vibrating equipment comprises a base, a vibrating screen body arranged at the top of the base, an oscillator arranged at the top of the vibrating screen body and a motor connected with the oscillator through a gear box. The monitoring system comprises a power monitoring module, a vibration monitoring module, a communication module and a remote terminal. The power monitoring module is used for monitoring operation data of the motor, the gearbox and the oscillator, and the vibration monitoring module is used for monitoring operation data of the vibrating screen body. According to the vibration screen, operation data of the motor, the gear box and the oscillator are monitored in real time through the power monitoring module, operation data of the vibration screen body are collected through the vibration monitoring module, and tiny abnormities in the equipment operation process can be found in time. Compared with a traditional manual inspection mode, fault deterioration caused by response lag is avoided.

Description

Technical Field

[0001] The present invention relates to the field of vibration equipment, and in particular to a vibration equipment monitoring system. Background Art

[0002] In industrial production, vibrating screens are critical equipment, and their stable operation is crucial for ensuring production efficiency and product quality. However, current traditional methods for detecting vibrating screen faults have many significant drawbacks. For one thing, traditional detection relies primarily on manual inspections, which suffer from significant response lags. Due to the periodicity and limitations of manual inspections, it's difficult to detect even subtle anomalies during equipment operation. These hidden defects are often difficult to detect initially, but if not discovered and addressed promptly, they can gradually worsen, ultimately leading to equipment failure and seriously impacting production continuity.

[0003] On the other hand, the currently widely used single-sensor monitoring method suffers from a serious lack of accuracy. The information captured by a single sensor is limited, making it difficult to fully and accurately reflect the actual operating status of the equipment, resulting in a high rate of false alarms. Furthermore, relying solely on single-sensor data makes it impossible to accurately locate the root cause of a fault, often leaving maintenance personnel at a loss as to where to begin, increasing the difficulty and time-consuming nature of troubleshooting and repair.

[0004] Sudden equipment failure will not only directly lead to production line shutdown, disrupt production plans, and cause huge economic losses, but will also seriously reduce the life of the equipment due to emergency repairs and abnormal equipment shutdowns, further increasing the company's operating costs. Summary of the Invention

[0005] In view of this, the present invention aims to provide a vibration equipment monitoring system to solve the problems in the prior art.

[0006] To achieve the above object, the technical solution of the present invention is achieved as follows: The present invention provides a vibration equipment monitoring system, wherein the vibration equipment includes a base, a vibrating screen body arranged on the top of the base, an agitator arranged on the top of the vibrating screen body, and a motor connected to the agitator through a gear box; The monitoring system includes a power monitoring module, a vibration monitoring module, a communication module, and a remote terminal; The power monitoring module is used to monitor the operating data of the motor, gearbox, and agitator; the vibration monitoring module is used to monitor the operating data of the vibrating screen body; and the communication module is used to transmit the data of the power monitoring module and the data of the vibration monitoring module to a remote terminal. The remote terminal determines whether the vibration equipment needs maintenance based on the data.

[0007] Furthermore, the power monitoring module includes a speed sensor provided at the end of the motor and a temperature sensor provided in the gear box; The speed sensor is used to detect the speed of the motor output shaft and transmit it to the remote terminal. The temperature sensor is used to collect the oil temperature of the lubricating oil in the gearbox and transmit it to the remote terminal.

[0008] Furthermore, an oil inlet pipe and an oil outlet pipe are connected in the gear box, and flow sensors are provided on the oil inlet pipe and the oil outlet pipe. The flow sensors are used to detect the flow rate of the lubricating oil entering the gear box.

[0009] Furthermore, the vibration monitoring module includes a vibration sensor fixedly arranged on one side of the vibrating screen body, and a pressure sensor arranged between the vibrating screen and the base; The vibration sensor is used to collect the vibration amplitude, speed and frequency of the vibration screen body, and the pressure sensor is used to collect the load-bearing capacity of the vibration screen body.

[0010] Furthermore, the vibration sensors are respectively located at the front and rear ends of the vibrating screen body.

[0011] Furthermore, the remote terminal is provided with an alarm threshold, and when one of the data of the power monitoring module and the vibration monitoring module exceeds the threshold, the remote terminal issues an alarm.

[0012] Furthermore, a storage unit is provided in the remote terminal for storing historical monitoring data of the power monitoring module and the vibration monitoring module.

[0013] Furthermore, the exciter is also provided with a plurality of vibration sensors for detecting the vibration frequency of the exciter.

[0014] Compared with the prior art, the present invention has the following advantages: In this invention, the vibration equipment monitoring system uses a power monitoring module to monitor the operating data of the motor, gearbox, and agitator in real time, while a vibration monitoring module collects operating data from the vibrating screen itself. This allows for the timely detection of subtle anomalies during equipment operation. Compared to traditional manual inspections, this system avoids the deterioration of faults caused by delayed response times.

[0015] The remote terminal accurately determines whether the vibration equipment needs maintenance based on the received data, achieving precise maintenance work. This eliminates the need for blind maintenance according to fixed cycles, reduces unnecessary maintenance costs and equipment downtime, and improves equipment utilization and production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings, which constitute part of the present invention, are provided to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are provided to explain the present invention and do not constitute an undue limitation of the present invention. In the accompanying drawings: Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 This is a structural diagram of the monitoring system of the present invention.

[0017] Description of reference numerals: 1. Base; 2. Vibrating screen body; 3. Agitator; 4. Motor; 401. Gearbox; 402. Oil inlet pipe; 403. Oil outlet pipe; 5. Temperature sensor; 6. Liquid level sensor; 7. Flow rate sensor; 8. Speed ​​sensor; 9. Vibration sensor; 10. Pressure sensor. DETAILED DESCRIPTION

[0018] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0019] In the description of the present invention, it should be noted that the terms "upper," "lower," "inner," and "back" and other terms indicating orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0020] Furthermore, in the description of the present invention, unless otherwise expressly defined, the terms "mounted," "connected," "connect," and "connector" should be interpreted broadly. For example, these terms may refer to fixed, removable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediary; or internal communication between two components. Those skilled in the art will appreciate the specific meanings of these terms in the present invention based on the specific circumstances.

[0021] The following will refer to the attached Figures 1 to 2 The present invention is described in detail with reference to the embodiments.

[0022] In general, the present invention relates to a vibration equipment monitoring system, wherein the vibration equipment comprises a base 1, a vibrating screen body 2 arranged on the top of the base 1, an agitator 3 arranged on the top of the vibrating screen body 2, and a motor 4 connected to the agitator 3 through a gear box 401; The monitoring system includes a power monitoring module, a vibration monitoring module, a communication module, and a remote terminal; The power monitoring module is used to monitor the operating data of the motor 4, gearbox 401, and agitator 3; the vibration monitoring module is used to monitor the operating data of the vibrating screen body 2; the communication module is used to transmit the data of the power monitoring module and the data of the vibration monitoring module to the remote terminal; the remote terminal determines whether the vibration equipment needs maintenance based on the data.

[0023] This vibration equipment monitoring system uses a power monitoring module to monitor the operating data of the motor 4, gearbox 401, and agitator 3 in real time, while a vibration monitoring module collects operating data from the vibrating screen body 2. This system can promptly detect subtle anomalies during equipment operation. Compared to traditional manual inspections, this system avoids faults that worsen due to delayed response times.

[0024] The remote terminal accurately determines whether the vibration equipment needs maintenance based on the received data, achieving precise maintenance work. This eliminates the need for blind maintenance according to fixed cycles, reduces unnecessary maintenance costs and equipment downtime, and improves equipment utilization and production efficiency.

[0025] The communication module transmits data from the power and vibration monitoring modules to a remote terminal in real time, enabling remote monitoring and management of equipment operating data. Maintenance personnel can access equipment operating status and fault information at any time through the remote terminal without having to visit the site, improving management efficiency.

[0026] The power monitoring module includes a speed sensor 8 provided at the end of the motor 4 and a temperature sensor 5 provided in the gear box 401; The speed sensor 8 is used to detect the speed of the output shaft of the motor 4 and transmit it to the remote terminal. The temperature sensor 5 is used to collect the oil temperature of the lubricating oil in the gear box 401 and transmit it to the remote terminal.

[0027] Speed ​​sensor 8, mounted at the end of motor 4, accurately and in real time detects the speed of motor 4's output shaft. Motor 4's speed is a crucial parameter reflecting its operating status. Continuous speed monitoring can promptly detect abnormal speed fluctuations, excessive speed, or low speed. For example, when the load on motor 4 suddenly increases, the speed may drop. Failure to detect and address this in a timely manner could lead to overheating or even damage. This monitoring system can detect speed changes in real time and issue early warnings, enabling maintenance personnel to take timely action to ensure stable operation of motor 4.

[0028] Temperature sensor 5 is installed in gearbox 401 and is specifically used to collect the temperature of the lubricating oil in gearbox 401. During operation, the friction between the gears of gearbox 401 generates a large amount of heat, which in turn increases the temperature of the lubricating oil. Proper oil temperature is crucial for the normal operation of gearbox 401. Excessively high oil temperature can degrade the lubricating oil's performance, accelerate gear wear, and even cause gearbox 401 to malfunction. By monitoring the oil temperature in real time, the system can promptly issue an alarm when the oil temperature exceeds the normal range, prompting maintenance personnel to take cooling measures, such as checking the cooling system and adjusting the lubricating oil flow rate, thereby effectively protecting gearbox 401 and extending its service life.

[0029] The power monitoring module monitors the speed of motor 4 and the oil temperature of gearbox 401 in real time, providing early warning signals before equipment failures occur. This significantly improves the timeliness of fault detection compared to traditional manual inspections. For example, a slight fluctuation in motor 4's speed may indicate a fault in its internal windings, while a sudden increase in gearbox 401's oil temperature may indicate increased gear wear or a cooling system failure. This early warning allows maintenance personnel to perform repairs and address the problem before it seriously impacts equipment operation, thus avoiding production interruptions and financial losses caused by sudden equipment failures.

[0030] In addition, a liquid level sensor 6 is provided in the gear box 401 , and the operator can know the amount of lubricating oil in the gear box 401 through the liquid level sensor 6 and determine whether to add oil or drain oil.

[0031] Gearbox 401 is interconnected with an oil inlet pipe 402 and an oil outlet pipe 403. Flow sensors are installed on the oil inlet pipe 402 and the oil outlet pipe 403 to detect the flow rate of lubricating oil entering gearbox 401. The flow sensors, installed on the oil inlet pipe 402 and the oil outlet pipe 403, can accurately and in real time detect the flow rate of lubricating oil entering gearbox 401. Lubricating oil flow rate is a key parameter reflecting the operating status of the lubrication system in gearbox 401. Real-time flow rate monitoring ensures that lubricating oil enters gearbox 401 at an appropriate flow rate, providing adequate lubrication for components such as gears and bearings. For example, if the flow rate is too low, the lubricating oil may not reach all friction points in a timely manner, increasing the risk of component wear. If the flow rate is too high, not only will the lubricating oil be wasted, but excessive oil pressure may also damage components such as the seals of gearbox 401. This monitoring system can promptly detect flow rate anomalies and ensure the lubrication of gearbox 401.

[0032] The vibration monitoring module includes a vibration sensor 9 fixedly arranged on one side of the vibrating screen body 2, and a pressure sensor 10 arranged between the vibrating screen and the base 1; the vibration sensor 9 is used to collect the vibration amplitude, speed and frequency of the vibrating screen body 2, and the pressure sensor 10 is used to collect the load-bearing capacity of the vibrating screen body 2.

[0033] Vibration sensor 9, fixed to one side of the vibrating screen body 2, accurately and in real time collects the vibration amplitude, velocity, and frequency of the vibrating screen body 2. These vibration parameters are key indicators of the vibrating screen's operating status. Excessive vibration amplitude can cause fatigue damage to the vibrating screen structure, abnormal vibration velocity can affect screening efficiency and material transport, and changes in vibration frequency may indicate potential malfunctions in internal equipment components. By continuously monitoring these parameters, we can fully understand the vibration characteristics of the vibrating screen and promptly identify potential problems.

[0034] Pressure sensor 10, positioned between the vibrating screen and base 1, accurately measures the load-bearing capacity of the vibrating screen body 2. During operation, the vibrating screen's load-bearing capacity changes as material is added and screened. Load-bearing data not only reflects the material load but also indirectly reflects the vibrating screen's structural strength and stability. For example, an abnormal increase in load-bearing capacity could indicate a material blockage or structural deformation. Promptly identifying and addressing these issues can prevent equipment damage and production accidents.

[0035] It should be noted that vibration sensors 9 are located at the front and rear ends of the vibrating screen body 2. Installing vibration sensors 9 at both ends of the vibrating screen body 2 allows for the collection of vibration data from different locations. During operation, the vibrating screen may experience different vibration conditions at different locations. The front sensor captures the vibration impact of material entering the screen, while the rear sensor reflects the vibration state of the material as it is discharged after screening.

[0036] It should be further explained that the remote terminal has an alarm threshold. When the data of one of the power monitoring module and the vibration monitoring module exceeds the threshold, the remote terminal will issue an alarm. The remote terminal is equipped with a storage unit for storing historical monitoring data of the power monitoring module and the vibration monitoring module.

[0037] The thresholds are determined based on the normal operating parameter range of the equipment, historical data statistics, and the recommendations of the equipment manufacturer. For example, for the lubricating oil flow rate of gearbox 401, an appropriate upper and lower flow rate threshold is set based on the model of gearbox 401, the load conditions, and the design requirements of the lubrication system. When the flow rate exceeds this range, it may mean that there is a problem with the lubrication system. For the vibration monitoring module, the vibration parameters at different locations will also be set with different thresholds based on the design specifications, working principles, and actual operating experience of the vibrating screen. For example, the threshold of the vibration amplitude will take into account factors such as the vibrating screen's screening efficiency, structural strength, and impact on the material.

[0038] During specific implementation, the power monitoring module continuously monitors the relevant power parameters of the vibrating screen. The gear box 401 lubricating oil flow rate sensor 7 senses the flow rate of the lubricating oil in the pipeline in real time and converts the physical flow rate signal into an electrical signal; the oil temperature sensor senses the change in oil temperature through the thermistor and outputs the corresponding electrical signal. In the vibration monitoring module, the vibration sensors 9 located at the front and rear ends of the vibrating screen body 2 play their respective roles. The front-end sensor captures the vibration of the vibrating screen when the material enters, and the rear-end sensor records the vibration state of the material when it is discharged after screening. They convert physical quantities such as vibration amplitude, speed and frequency into electrical signals to ensure that the collected data fully reflects the vibration characteristics of the vibrating screen.

[0039] Collected power and vibration monitoring data is transmitted to the communication module via wired or wireless means. Wired transmission uses cables to connect the sensor to the communication module, offering stable signal transmission and strong interference resistance, making it suitable for industrial environments requiring high data reliability. Wireless transmission utilizes technologies such as Wi-Fi and ZigBee, offering the advantages of easy installation and high flexibility, making it suitable for applications where wiring is difficult. After receiving the sensor signal, the communication module encodes and modulates it, converting the signal into a format suitable for transmission over the communication network. The data is then transmitted to a remote terminal via wireless communication networks (such as 4G / 5G) or wired networks (such as Ethernet).

[0040] The storage unit in the remote terminal stores the received power and vibration monitoring data in chronological order to facilitate the operator's future query.

[0041] In addition, a plurality of vibration sensors 9 are also provided on the exciter 3 for detecting the vibration frequency of the exciter 3 .

[0042] During operation, the vibrator 3 often exhibits specific vibration frequency variations when different components malfunction. For example, bearing wear on the vibrator 3 can cause abnormal vibration frequencies during rotation. Multiple vibration sensors 9, located at key locations on the vibrator 3, can capture these subtle frequency variations in real time. By comparing and analyzing the vibration frequency data with normal conditions, early warnings can be issued to prevent further deterioration, reducing equipment damage and repair costs.

[0043] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A vibration equipment monitoring system, characterized in that: The vibration device comprises a base (1), a vibration screen body (2) arranged on the top of the base (1), an agitator (3) arranged on the top of the vibration screen body (2), and a motor (4) connected to the agitator (3) via a gear box (401); The monitoring system includes a power monitoring module, a vibration monitoring module, a communication module, and a remote terminal; The power monitoring module is used to monitor the operating data of the motor (4), the gear box (401), and the agitator (3); the vibration monitoring module is used to monitor the operating data of the vibrating screen body (2); and the communication module is used to transmit the data of the power monitoring module and the data of the vibration monitoring module to a remote terminal, and the remote terminal determines whether the vibration equipment needs maintenance based on the data.

2. A vibration equipment monitoring system according to claim 1, characterized in that: The power monitoring module includes a rotation speed sensor (8) provided at the end of the motor (4), and a temperature sensor (5) provided in the gear box (401); The speed sensor (8) is used to detect the speed of the output shaft of the motor (4) and transmit it to the remote terminal. The temperature sensor (5) is used to collect the oil temperature of the lubricating oil in the gear box (401) and transmit it to the remote terminal.

3. A vibration equipment monitoring system according to claim 2, characterized in that: An oil inlet pipe (402) and an oil outlet pipe (403) are connected in the gear box (401), and flow sensors are provided on the oil inlet pipe (402) and the oil outlet pipe (403). The flow sensors are used to detect the flow rate of lubricating oil entering the gear box (401).

4. A vibration equipment monitoring system according to claim 1, characterized in that: The vibration monitoring module comprises a vibration sensor (9) fixedly arranged on one side of the vibrating screen body (2), and a pressure sensor (10) arranged between the vibrating screen and the base (1); The vibration sensor (9) is used to collect the vibration amplitude, speed and frequency of the vibrating screen body (2), and the pressure sensor (10) is used to collect the load-bearing capacity of the vibrating screen body (2).

5. A vibration equipment monitoring system according to claim 1, characterized in that: The vibration sensors (9) are respectively located at the front and rear ends of the vibration screen body (2).

6. A vibration equipment monitoring system according to claim 1, characterized in that: The remote terminal is provided with an alarm threshold, and when one of the data of the power monitoring module and the vibration monitoring module exceeds the threshold, the remote terminal issues an alarm.

7. A vibration equipment monitoring system according to claim 6, characterized in that: The remote terminal is provided with a storage unit for storing historical monitoring data of the power monitoring module and the vibration monitoring module.

8. A vibration equipment monitoring system according to claim 4, characterized in that: The exciter (3) is also provided with a plurality of vibration sensors (9) for detecting the vibration frequency of the exciter (3).

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