Industrial mobile power supply fan blockage early warning control method and system

Abstract

The invention relates to the technical field of electric digital data processing, and discloses an industrial mobile power supply fan blockage early warning control method which comprises the following steps: S1, acquiring a CLOCK signal: acquiring a clock square wave signal from a Hall sensor arranged in a fan; s2, calculating the rotating speed: calculating the rotating speed of a fan according to the clock square wave signal; s3, calculating a deviation ratio: calculating the deviation ratio according to the fan rotating speed and the reference rotating speed; s4, early warning grading: judging the early warning grade according to the deviation rate; and S5, executing early warning: triggering and executing an early warning action according to the early warning level. Clock square wave signals of the rotating speed are directly collected through the Hall sensor, the mechanical performance of the fan is reflected in real time, uncertainty of indirect parameters is avoided, direct rotating speed monitoring replaces the indirect parameters, the problem of response lag caused by sediment environment signal interference is effectively solved, and the real-time performance of the fan is improved based on a dynamic reference and grading early warning mechanism. The crossing from'fault post-processing 'to'prevention before blockage' is realized, and the requirement of a mobile power supply on a construction site can be accurately matched.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electric digital data processing, in particular to the technical field of detecting power failure through transfinite supervision. BACKGROUND

[0002] Industrial mobile power supply is widely used as a diesel generator substitute on the construction site, but it faces the serious challenge of sand invasion. The main reason is that the high dust environment on the construction site causes 0.1-1mm sand particles to penetrate the dust screen, and the actual measurement data shows that the wind volume of the fan blades will decrease by 30-60% after the sand is attached, which will directly cause the temperature of the battery compartment of the industrial mobile power supply to rise by 15-25℃, and the cycle life of the lithium battery to decrease by 40%.

[0003] The inventor found that at least the following problems exist in the prior art: fan blockage is mainly inferred indirectly by relying on current fluctuation or temperature, and its theoretical basis is that the current increases sharply and the temperature rises significantly when the motor is blocked, but from a technical practice point of view, the sand environment on the construction site is easy to cause the current signal to be disturbed and misjudged, so its response is very lagging, and it often has an actual response only when the temperature abnormally rises by more than 10℃. In order to solve this problem, various further sand prevention measures are added to the prior art, which increases the cost by more than 35%, but the timeliness of the sand prevention response cannot be effectively solved. Therefore, a further technical solution adopts fixed interval period to remind manual inspection of the blind area, but it still only treats the symptoms and not the root cause. SUMMARY

[0004] The purpose of the present application is to provide an industrial mobile power supply fan blockage early warning control method, which fundamentally solves the problem of abnormal response efficiency of fan blockage.

[0005] To solve the above technical problems, the present application provides an industrial mobile power supply fan blockage early warning control method, comprising the following steps: S1, collecting a CLOCK signal: obtaining a clock square wave signal from a Hall sensor built in the fan; S2, calculating the rotational speed: calculating the fan rotational speed according to the clock square wave signal; S3, calculating the deviation rate: calculating the deviation rate according to the fan rotational speed and the reference rotational speed; S4, early warning grading: judging the early warning level according to the deviation rate; S5, executing early warning: triggering the execution of early warning actions according to the early warning level.

[0006] The reference rotational speed is the fan no-load rotational speed, which is recorded and stored at the first start.

[0007] After the step S1, filtering and shaping processing is further performed.

[0008] The filter shaping processing adopts a sliding average filter, and the sliding window is 5 seconds.

[0009] The deviation rate is calculated in the following manner: , In the formula, is a reference rotating speed, is a fan rotating speed.

[0010] The pre-warning level includes four levels, namely, no pre-warning, first-level visual pre-warning, second-level sound-light pre-warning, and third-level emergency treatment. The pre-warning level is determined according to the deviation rate in the following manner: <15%, the pre-warning level is no pre-warning; 15%≤ ≤30%, the pre-warning level is first-level visual pre-warning; 30%≤ ≤45%, the pre-warning level is second-level sound-light pre-warning; ≥45%, the pre-warning level is third-level emergency treatment.

[0011] The first-level visual pre-warning triggers the pre-warning action of lighting a preset LED, the second-level sound-light pre-warning triggers the pre-warning action of lighting the preset LED and starting an alarm speaker or an alarm buzzer, and the third-level emergency treatment triggers the pre-warning action of lighting the preset LED, starting the alarm speaker or the alarm buzzer, and limiting the output power of the fan.

[0012] The fan is an IP67 waterproof level fan.

[0013] The application further provides an industrial mobile power fan blockage pre-warning control method, comprising: a data acquisition module configured to perform steps S1 and S2 in the industrial mobile power fan blockage pre-warning control method as described above; a control unit configured to perform steps S3 and S4 in the industrial mobile power fan blockage pre-warning control method as described above; an execution unit configured to perform step S5 in the industrial mobile power fan blockage pre-warning control method as described above.

[0014] The application further provides a computer readable storage medium storing a computer program, wherein the computer program is executed by a processor to implement the industrial mobile power fan blockage pre-warning control method as described above.

[0015] Compared with the prior art, the clock square wave signal of the rotating speed is directly collected by the Hall sensor, the mechanical performance of the fan is reflected in real time, the uncertainty of the indirect parameter is avoided, the direct rotating speed monitoring is replaced by the indirect parameter, the response lag problem caused by the signal interference of the silt environment is effectively solved, and based on the dynamic reference + hierarchical early warning mechanism, the leap from "fault processing" to "blockage prevention" is realized, and the demand of the construction site mobile power supply can be accurately matched.

[0016] In addition, the present application can effectively reduce the maintenance cost, reduce the frequency of fan hardware replacement, and based on the power limiting function, avoid the fire caused by the stall overheating, greatly improve the safety, and the lightweight algorithm can be transplanted to other industrial heat dissipation scenes, and the expansion applicability is excellent.

[0017] The above description is only a summary of the technical solutions of the present application, in order to more clearly understand the technical means of the present application, the contents of the specification can be implemented, and in order to make the above and other purposes, characteristics and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application are described below. BRIEF DESCRIPTION OF DRAWINGS

[0018] One or more embodiments are illustrated by the pictures in the corresponding drawings, which do not constitute a limitation on the embodiments, and elements with the same reference numerals in the drawings represent similar elements, unless otherwise specified, and the drawings do not constitute a proportional limitation.

[0019] Figure 1 is a flowchart of at least one embodiment of the present application; Figure 2 is a connection and data flow diagram of at least one embodiment of the present application; Figure 3 is a flowchart of an experiment in the present application. DETAILED DESCRIPTION

[0020] In order to make the purposes, technical solutions and advantages of the present application more clear, the embodiments of the present application will be described in detail below with reference to the drawings. However, those skilled in the art can understand that in the embodiments of the present application, many technical details are proposed in order to make the reader better understand the present application. However, even without these technical details and various changes and modifications based on the following embodiments, the technical solutions claimed by the present application can be realized. The following embodiments are divided for the convenience of description, and should not constitute any limitation on the specific embodiments of the present application, and the embodiments can be combined with each other under the premise of not contradicting.

[0021] The first embodiment of the present application relates to a fan blockage early warning control method of industrial mobile power supply, comprising the following steps: S1, collect the clock signal: obtain the clock square wave signal from the fan built-in hall sensor; S2, calculate the rotation speed: calculate the fan rotation speed according to the clock square wave signal; S3, calculate the deviation rate: calculate the deviation rate according to the fan rotation speed and the reference rotation speed; S4, early warning classification: determine the early warning level according to the deviation rate; S5, execute the early warning: trigger the execution of the early warning action according to the early warning level.

[0022] The step division of the above methods is only for the purpose of clear description, and in implementation, one step can be combined or some steps can be split and decomposed into multiple steps, as long as the same logical relationship is included, all within the protection scope of the patent; adding insignificant modifications or introducing insignificant designs in the algorithm or process, but not changing the core design of the algorithm and process, are within the protection scope of the patent.

[0023] Therefore, the present embodiment can realize early warning of blockage, achieve the purpose of maintenance guidance without disassembly and prevention of battery thermal runaway. Generally, in practice, the fan reverse dust removal (6000 rpm reverse for 3 seconds) should be automatically executed every week based on the present embodiment, and the blockage degree is estimated according to the ΔR growth rate, and except in emergency situations, the cumulative early warning time > 0.5 hours should trigger a special reminder.

[0024] The second embodiment of the present application is substantially the same as the first embodiment, and the main difference is that the reference rotation speed is the fan no-load rotation speed, which is recorded and stored at the first start.

[0025] After the step S1, a filtering and shaping process is also performed. Generally, in practice, a pulse interval mutation > 20% should also be discarded automatically.

[0026] The filtering and shaping process uses a sliding average filter with a sliding window of 5 seconds. It is easy to understand that a 10 ms sampling window count is generally used.

[0027] The deviation rate is calculated in the following way: , In the formula, is the reference rotation speed, is the fan rotation speed.

[0028] The early warning level includes four levels, namely no early warning, one-level visual early warning, two-level sound and light early warning, and three-level emergency treatment; in step S4, the early warning level is determined according to the deviation rate as follows: <15%, the early warning level is no early warning; 15%≤ ≤ 30%, the early warning level is a first visual early warning; 30%≤ ≤ 45%, the early warning level is a second sound-light early warning; ≥ 45%, the early warning level is a third emergency treatment.

[0029] The first visual early warning triggers an execution early warning action of lighting a preset LED, the second sound-light early warning triggers an execution early warning action of lighting the preset LED and starting an alarm speaker or an alarm buzzer, and the third emergency treatment triggers an execution early warning action of lighting the preset LED, starting the alarm speaker or the alarm buzzer, and limiting the output power of the fan.

[0030] The fan is an IP67 waterproof level fan. Generally, the fan adopts a side hanging type air duct, and an external honeycomb type detachable double-stage filter screen (an outer layer of stainless steel screen + an inner layer of magnetic absorption filter cotton).

[0031] It can be found that the embodiment is a system embodiment corresponding to the first embodiment, and the embodiment can be implemented in cooperation with the first embodiment. The related technical details mentioned in the first embodiment are still effective in the embodiment, and in order to reduce repetition, they will not be described here. Correspondingly, the related technical details mentioned in the embodiment can also be applied in the first embodiment.

[0032] The third embodiment of the present application relates to an industrial mobile power supply fan blockage early warning control method as shown in Figure 2 The method comprises the following steps: The data acquisition module is used for executing steps S1 and S2 in the first embodiment and the second embodiment; The control unit is used for executing steps S3 and S4 in the first embodiment and the second embodiment; The execution unit is used for executing step S5 in the first embodiment and the second embodiment.

[0033] It can be found that the embodiment is a system embodiment corresponding to the first embodiment, and the embodiment can be implemented in cooperation with the first embodiment. The related technical details mentioned in the first embodiment are still effective in the embodiment, and in order to reduce repetition, they will not be described here. Correspondingly, the related technical details mentioned in the embodiment can also be applied in the first embodiment.

[0034] It is worth mentioning that each module involved in the embodiment is a logical module. In actual application, a logical unit can be a physical unit, a part of a physical unit, or a combination of multiple physical units. In addition, in order to highlight the innovative part of the present application, units not closely related to solving the technical problems proposed in the present application are not introduced in the embodiment, but this does not mean that there are no other units in the embodiment.

[0035] A fourth embodiment of the present application relates to a computer readable storage medium storing a computer program, which, when executed by a processor, implements the first and second embodiments.

[0036] That is, those skilled in the art can understand that all or part of the steps of the above-mentioned embodiment methods can be completed by programs instructing relevant hardware, the programs being stored in a storage medium and including a plurality of instructions for causing a device (which can be a single-chip microcomputer, a chip, etc.) or a processor to execute all or part of the steps of the methods described in the various embodiments of the present application. The aforementioned storage medium includes a U disk, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, and various media that can store program codes.

[0037] Experimental Example 1 Based on the above-mentioned embodiments, experiments were carried out using the flowchart shown in Figure 3 The following technical indicators were achieved in the experiments: Threshold accuracy: the error of each level of early warning triggering is less than or equal to 0.8%, meeting the design index of ±1%.

[0038] Response speed: The average time of the first level of early warning is 4.9 seconds (the requirement is less than or equal to 5 seconds).

[0039] The time of the third level of early warning is only 1.6 seconds (faster than the requirement of 2 seconds).

[0040] Reliability: Zero false positives under voltage fluctuation / high-temperature environment.

[0041] False positive rate under mechanical vibration scene is less than or equal to 10%.

[0042] Protection effect: When ΔR=50%, the wind speed decreases by 77.6%.

[0043] The power limiting action time is 0.2 seconds, effectively preventing overheating.

[0044] Those skilled in the art can understand that the above-mentioned embodiments are specific embodiments for implementing the present application, and in actual applications, various changes can be made in form and details without departing from the spirit and scope of the present application.

Claims

1. An industrial mobile power supply fan blockage early warning control method, characterized in that, Comprising the following steps: S1, collecting a clock signal: obtaining a clock square wave signal from a Hall sensor built in the fan; S2, calculating the rotation speed: calculating the fan rotation speed according to the clock square wave signal; S3, calculating the deviation rate: calculating the deviation rate according to the fan rotation speed and the reference rotation speed; S4, early warning classification: judging the early warning level according to the deviation rate; S5, executing early warning: triggering the execution of early warning actions according to the early warning level.

2. The method of claim 1, wherein the method further comprises: The reference rotation speed is the fan idle rotation speed, which is recorded and stored at the first start.

3. The method of claim 1, wherein the method further comprises: After the step S1, a filtering and shaping process is further performed.

4. The method of claim 3, wherein the method further comprises: The filtering and shaping process adopts a sliding average filter, and the sliding window is 5 seconds.

5. The method of claim 1, wherein the method further comprises: The deviation rate is calculated in the following way: ， In the formula, is the reference rotational speed, is the fan rotational speed.

6. The method of claim 1, wherein the method further comprises: The pre-warning levels include four levels, respectively, no pre-warning, first level visual pre-warning, second level sound and light pre-warning, and third level emergency treatment; in step S4, the pre-warning level is determined according to the deviation rate in the following manner determination: <15%, the pre-warning level is no pre-warning; 15%≤ ≤30%, the pre-warning level is first level visual pre-warning; 30%≤ ≤45%, the pre-warning level is second level sound and light pre-warning; ≥45%, the pre-warning level is third level emergency treatment.

7. The method of claim 1, wherein the method further comprises: The execution of early warning triggered by the first-level visual early warning is to light up the preset LED, the execution of early warning triggered by the second-level sound-light early warning is to light up the preset LED and start the alarm speaker or alarm buzzer, and the execution of early warning triggered by the third-level emergency treatment is to light up the preset LED, start the alarm speaker or alarm buzzer, and limit the output power of the fan.

8. The method of claim 1, wherein the method further comprises: The fan is an IP67 waterproof level fan.

9. An industrial mobile power supply fan blockage early warning control method, characterized in that, Comprising: a data acquisition module for executing steps S1 and S2 in the industrial mobile power fan blockage early warning control method according to any one of claims 1 to 8; a control unit for executing steps S3 and S4 in the industrial mobile power fan blockage early warning control method according to any one of claims 1 to 8; an execution unit for executing step S5 in the industrial mobile power fan blockage early warning control method according to any one of claims 1 to 8.

10. A computer readable storage medium storing a computer program, characterized in that, The computer program, when executed by a processor, implements the industrial mobile power fan blockage early warning control method according to any one of claims 1 to 8.

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