Motor operation monitoring system, method and device, computer equipment and storage medium

Abstract

The invention relates to the technical field of motor digital monitoring, and discloses a motor operation monitoring system, method and device, computer equipment and a storage medium, in the system, an upper computer carries out parameter initialization configuration on a target control and monitor, and issues a periodic motor operation control instruction and a query instruction to the target control and monitor; the control and monitor obtains motor operation parameters through the motor controller, carries out data packaging on the motor operation parameters and initial configuration parameters, uploads the packaged parameters to the data receiving and processing terminal, and sends a periodic motor operation control instruction and a query instruction issued by the upper computer to the motor controller. And sending the control instruction to the server, so that the motor operates under a preset working condition according to the control instruction, feeding back corresponding query parameters to the control and monitoring device according to the query instruction, and performing differential analysis processing on the motor according to different motor types through the server. According to the invention, the problems that the parameters cannot be configured and the operation parameters are difficult to adapt to different scenes during motor monitoring are solved.

Description

Technical Field

[0001] This invention relates to the field of digital monitoring technology for electric motors, specifically to electric motor operation monitoring systems, methods, devices, computer equipment, and storage media. Background Technology

[0002] Existing motor monitoring systems often rely on additional sensors (such as speed sensors and voltage sensors) to obtain operating parameters. This not only increases hardware costs and equipment size but also requires complex wiring and installation procedures, making them particularly difficult to adapt to mobile scenarios or small motor equipment. Furthermore, different types of motor controllers use different communication protocols and signal links, making it difficult for general monitoring solutions to be compatible with multiple types of equipment. Customized interfaces need to be developed for specific controllers, which places high demands on the field. In some application sites, the necessary sensors or sensor installation conditions may not be available, resulting in poor adaptability and high development costs, thus limiting the application of such monitoring solutions.

[0003] In terms of command interaction, traditional systems often experience busy signal issues due to conflicting sending times between control and query commands, leading to delayed motor response or lost parameter data, thus affecting the real-time performance and reliability of monitoring. In data transmission, electromagnetic interference in industrial environments makes data susceptible to contamination during transmission. Traditional verification mechanisms often use a single checksum, which is insufficient to fully guarantee data integrity, potentially causing the server to receive erroneous data and impacting subsequent analysis results.

[0004] Therefore, there is an urgent need for a solution that allows for configurable parameters and the acquisition of motor operating parameters via the motor controller signal lines. Summary of the Invention

[0005] In view of this, the present invention provides a motor operation monitoring system, method, device, computer equipment and storage medium to solve the problems of non-configurable parameters and difficulty in adapting motor operation parameters to different scenarios in traditional motor monitoring.

[0006] In a first aspect, the present invention provides a motor operation monitoring system, the system comprising:

[0007] The system includes a host computer, at least one motor controller, at least one controller and monitor, and a data receiving and processing terminal; the controller and monitor are connected in communication with the motor controller, and the data receiving and processing terminal is connected to the controller and monitor.

[0008] The host computer is used to initialize and configure the parameters of the target controller and monitor, and to send periodic motor operation control commands and motor operation query commands to the target controller and monitor after the initialization and configuration are completed.

[0009] The controller and monitor are used to acquire motor operating parameters through the motor controller, package the motor operating parameters and initialization configuration parameters into a preset data structure and upload them to the data receiving and processing terminal, and send the periodic motor operation control commands and motor operation query commands issued by the host computer to the motor controller.

[0010] The motor controller is used to control the motor body to operate under preset conditions according to the motor operation control command, and to feed back the corresponding query parameters to the controller and monitor according to the motor operation query command;

[0011] The data receiving and processing terminal is used to package data packets based on the controller and monitor, and to perform differentiated analysis and processing on motors of different types.

[0012] This invention provides a motor operation monitoring system that eliminates the need for additional detection sensors. The controller and monitor directly communicate with the motor controller to acquire parameters and control the motor, significantly reducing hardware procurement costs. Simultaneously, it eliminates the need for sensor wiring and installation, simplifying the system deployment process. This is particularly suitable for mobile scenarios or small motor equipment, reducing on-site construction complexity and time costs. Addressing the protocol differences of different motor controllers, the host computer can flexibly set core parameters through parameter initialization configuration. The controller and monitor achieve cross-protocol compatibility based on configuration commands, eliminating the need to develop customized interfaces for specific motor controllers. This significantly reduces the development cost of adapting the system to multiple types of equipment and expands the system's applicability. The controller and monitor execute periodic commands issued by the host computer, innovatively employing an ordered sending mechanism for control and query commands. This avoids the command line conflict problem in traditional systems, ensuring real-time response of the motor controller to control commands and accurate acquisition of operating parameters. The data receiving and processing terminal can meet the needs of wireless remote monitoring and supports efficient local wired analysis, improving the flexibility and data processing efficiency of centralized management of multiple devices. This solves the problems of unconfigurable parameters and difficulty in adapting motor operating parameter acquisition to different scenarios in traditional motor monitoring.

[0013] In one optional implementation, the host computer is also used to access the target address of the target controller and monitor via a local address or a unique ID, and to perform parameter initialization configuration of the target controller and monitor based on the target address.

[0014] This invention provides a motor operation monitoring system. Each controller and monitor is assigned a globally unique ID, enabling accurate target device location even in scenarios with dense multi-device deployments (such as multiple production lines and parallel monitoring of multiple types of motors), avoiding misoperations caused by duplicate or conflicting local area addresses. The local area address is suitable for rapid identification within a small local area network. The combination of these two methods forms a multi-dimensional device location system, ensuring that initialization configuration commands are accurately delivered to the target device.

[0015] In one optional implementation, the host computer is also used to issue periodic motor operation control commands and motor operation query commands in a cross-transmission manner.

[0016] The present invention provides a motor operation monitoring system. The cross-transmission mechanism, through strict timing planning, enables two types of instructions to be executed alternately on the time axis (e.g., sending a control instruction first and waiting for the response before sending a query instruction). This fundamentally eliminates link occupancy conflicts at the same time, ensures the accurate response of the motor controller to control instructions such as speed and torque, and the real-time nature of operating parameter queries, thereby improving the stability of the communication link.

[0017] In one optional implementation, the motor operating parameters include input voltage command, output power command, output torque command, operating speed command, cumulative start-stop count, and cumulative running time; the initialization configuration parameters include the type of motor to be monitored, uplink and downlink communication configuration parameters, and a checksum obtained by clearing historical data of the device.

[0018] The controller and monitor are also used to package input voltage commands, output power commands, output torque commands, operating speed commands, cumulative start-stop counts, cumulative running time, type of motor to be monitored, uplink and downlink communication configuration parameters, checksum, local area address, and unique ID according to a preset data structure.

[0019] This invention provides a motor operation monitoring system that packages data covering the core direct parameters of motor operation (input voltage command, output power command, output torque command, and operating speed command), key indirect data (cumulative start-stop count and cumulative running time), basic configuration information (type of motor to be monitored, uplink and downlink communication configuration parameters), and identification (local address and unique ID). This integration of multi-dimensional data avoids the information fragmentation problem caused by traditional single-parameter transmission, providing a complete data foundation for the server to subsequently analyze the motor's operating status, assess its lifespan, and diagnose faults, ensuring more comprehensive and accurate analysis results.

[0020] In one alternative implementation, the data receiving and processing terminal includes a cloud server and a local server. The cloud server is wirelessly connected to the controller and monitor, and the local server is wirelessly or wiredly connected to the controller and monitor.

[0021] This invention provides a motor operation monitoring system. A cloud server connects wirelessly to the controller and monitor, eliminating the limitations of geographical distance and cabling. Even when the controller and monitor are in mobile scenarios (such as outdoor testing) or distributed deployments, real-time data uploads can be achieved, meeting the needs of remote monitoring and cross-regional data aggregation. The local server supports wireless or wired (such as Ethernet) connections. In fixed factory areas, laboratories, and other scenarios, the appropriate connection can be chosen based on the network environment: wired connections ensure high-bandwidth, low-latency data transmission, while wireless connections simplify local network cabling. The combination of these two methods allows the system to adapt to complex and diverse industrial environments.

[0022] In one alternative implementation, the system further includes: at least two motor controllers, a master controller and monitor, and at least two slave controllers and monitors; the master controller and monitor includes a wireless routing module;

[0023] Each motor controller is connected to a controller and monitor.

[0024] At least two controllers and monitors are connected to the wireless router module in parallel.

[0025] The main controller and monitor is used to forward its own data, as well as data from each slave controller and monitor, to the cloud server and / or local server.

[0026] This invention provides a motor operation monitoring system in which at least two slave controllers and monitors are connected in parallel to the wireless routing module of the master controller and monitor. This eliminates the need for separate wireless transmission modules or wired links for each slave device, significantly reducing hardware wiring costs and construction complexity in multi-motor monitoring scenarios. The centralized networking design of the master-slave architecture eliminates the need for complex network topology configurations when deploying multiple motor controllers. Data aggregation and forwarding can be achieved solely through the wireless routing module of the master controller and monitor, significantly improving the convenience and efficiency of multi-device networking. This architecture can be extended to monitor multiple motors in close proximity within the same area.

[0027] In a second aspect, the present invention provides a motor operation monitoring method, applied to a motor operation monitoring system according to the first aspect above or any corresponding embodiment thereof, the method comprising:

[0028] The host computer is used to initialize and configure the parameters of the target controller and monitor, and then sends periodic motor operation control commands and motor operation query commands to the target controller and monitor after the initialization and configuration are completed.

[0029] The controller and monitor acquire motor operating parameters through the motor controller, and upload the motor operating parameters and initialization configuration parameters to the data receiving and processing terminal after packaging the data according to the preset data structure. The controller also sends the periodic motor operation control commands and motor operation query commands issued by the host computer to the motor controller.

[0030] The motor controller controls the motor body to operate under preset conditions according to the motor operation control command, and feeds back the corresponding query parameters to the controller and monitor according to the motor operation query command;

[0031] The data receiving and processing terminal uses data packets packaged from the controller and monitor to perform differentiated analysis and processing on motors of different types.

[0032] This invention provides a motor operation monitoring method that eliminates the need for additional detection sensors. The controller and monitor directly communicate with the motor controller to acquire parameters and control the motor, significantly reducing hardware procurement costs. Simultaneously, it eliminates the need for sensor wiring and installation, simplifying the system deployment process. This is particularly suitable for mobile scenarios or small motor equipment, reducing on-site construction complexity and time costs. Addressing the protocol differences between different motor controllers, the host computer can flexibly set core parameters through parameter initialization configuration. The controller and monitor achieve cross-protocol compatibility based on configuration commands, eliminating the need to develop customized interfaces for specific motor controllers. This significantly reduces the development cost of adapting the system to multiple types of equipment and expands the system's applicability. By executing periodic commands issued by the host computer, the controller and monitor innovatively adopt an ordered sending mechanism for control and query commands, avoiding the command line conflict problem in traditional technologies. This ensures the motor controller's real-time response to control commands and accurate acquisition of operating parameters. The dual-option design of cloud server and local server not only meets the needs of wireless remote monitoring, but also supports efficient local wired analysis, which improves the flexibility and data processing efficiency of centralized management of multiple devices, and solves the problems of unconfigurable parameters and difficulty in adapting motor operation parameters to different scenarios in traditional motor monitoring.

[0033] Thirdly, the present invention provides a motor operation monitoring device, applied to the motor operation monitoring system of the first aspect or any corresponding embodiment described above, the device comprising:

[0034] The initialization configuration and command issuance module is used to initialize the parameters of the target controller and monitor using the host computer, and to issue periodic motor operation control commands and motor operation query commands to the target controller and monitor after the initialization configuration is completed.

[0035] The data packaging and instruction sending module is used to obtain motor operating parameters through the motor controller using the controller and monitor, and to package the motor operating parameters and initialization configuration parameters into a preset data structure and upload them to the data receiving and processing terminal. It also sends the periodic motor operation control instructions and motor operation query instructions issued by the host computer to the motor controller.

[0036] The motor control module is used to control the motor body to operate under preset conditions according to the motor operation control command, and to feed back the corresponding query parameters to the controller and monitor according to the motor operation query command;

[0037] The differentiation processing module is used to perform differentiated analysis and processing on motors based on different motor types by using data packets packaged by the data receiving and processing terminal based on the controller and monitor.

[0038] Fourthly, the present invention provides a computer device, comprising: a memory and a processor, wherein the memory and the processor are communicatively connected to each other, the memory stores computer instructions, and the processor executes the computer instructions to perform the motor operation monitoring method of the second aspect described above.

[0039] Fifthly, the present invention provides a computer-readable storage medium storing computer instructions for causing a computer to execute the motor operation monitoring method of the second aspect described above.

[0040] In a sixth aspect, the present invention provides a computer program product, including computer instructions for causing a computer to execute the motor operation monitoring method described in the second aspect above. Attached Figure Description

[0041] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0042] Figure 1 This is a schematic diagram of the structure for monitoring motor operation according to an embodiment of the present invention;

[0043] Figure 2This is a schematic diagram of another motor operation monitoring system according to an embodiment of the present invention;

[0044] Figure 3 This is a flowchart illustrating a motor operation monitoring method according to an embodiment of the present invention;

[0045] Figure 4 This is a schematic diagram of the process of the host computer performing parameter initialization configuration on the controller and monitor according to an embodiment of the present invention;

[0046] Figure 5 This is a schematic diagram of the cross sequence of motor operation control instructions and motor operation query instructions according to an embodiment of the present invention;

[0047] Figure 6 This is a schematic diagram of the network packet composition of the JSON data structure according to an embodiment of the present invention;

[0048] Figure 7 This is a schematic diagram of the structure of another motor operation monitoring system according to an embodiment of the present invention;

[0049] Figure 8 This is a flowchart illustrating another motor operation monitoring method according to an embodiment of the present invention;

[0050] Figure 9 This is a structural block diagram of a motor operation monitoring device according to an embodiment of the present invention;

[0051] Figure 10 This is a schematic diagram of the hardware structure of a computer device according to an embodiment of the present invention. Detailed Implementation

[0052] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Currently, a common solution is to collect various parameters of the motor during operation through various external sensors and forward them to the terminal using a hub.

[0053] The specific implementation process includes: using a tachometer to detect the motor speed, a torque meter to detect the motor output torque, and a wattmeter to detect the input voltage, input current, and input power of the motor controller. The data is then transmitted to a PC for processing and analysis via a hub. Various parameters of the motor during operation are collected from external sensors and forwarded to the terminal using a data acquisition module.

[0054] The above solutions still have problems or shortcomings: they have high requirements for the site, and the required sensors or sensor installation conditions are often not available at the application site. The wiring is complicated and costly, which limits the application of this type of monitoring solution.

[0055] A few manufacturers use communication methods to monitor the motor's operating status: This solution requires separate debugging for motor controllers with different protocol types, which greatly increases the adaptation work and reduces flexibility.

[0056] This invention provides a motor operation monitoring system. The system analyzes and monitors different signals from the motor controller without requiring additional detection sensors. The controller and monitor communicate directly with the motor controller to acquire parameters and control the motor, significantly reducing hardware procurement costs. Addressing the protocol differences between different motor controllers, the host computer can flexibly set core parameters through parameter initialization configuration. The controller and monitor achieve cross-protocol compatibility based on configuration commands, eliminating the need to develop customized interfaces for specific motor controllers. This significantly reduces the development cost of adapting the system to multiple types of equipment and expands the system's applicability.

[0057] This embodiment provides a motor operation monitoring system. Figure 1 This is a schematic diagram of the structure of motor operation monitoring according to an embodiment of the present invention, as shown below. Figure 1 As shown, the system includes:

[0058] The system includes a host computer, at least one motor controller, at least one controller and monitor, and a data receiving and processing terminal; the controller and monitor are connected in communication with the motor controller, and the data receiving and processing terminal is connected to the controller and monitor.

[0059] Specifically, such as Figure 2 As shown, the motor controller is connected to the motor body. The signal or communication line of the motor controller is connected to the controller and monitor. The controller and monitor are connected to the data receiving and processing terminal via wireless 4G or wired connection. The data receiving and processing terminal includes a cloud server and a local server. The cloud server is connected to the controller and monitor wirelessly, and the local server is connected to the controller and monitor wirelessly or via wired connection. This controller and monitor is a digital controller and monitor.

[0060] It should be noted that the communication connection between the digital controller and the motor controller can be any mainstream communication method currently available, including but not limited to industrial communication methods such as RS422 and CAN communication; the connection between the controller and the data receiving terminal can be achieved by wirelessly connecting to the cloud server or by wireless / wired connecting to the local server. Wireless methods include but are not limited to 4G and WIFI, while wired methods are achieved through network cables.

[0061] The motor controller includes: 1. an industrial communication circuit with RS-485 (Recommended Standard 485, industrial communication interface standard); 2. an RT communication circuit (Real-Time communication circuit); and 3. an FG (Frequency Generator) circuit. The first two use serial communication lines to interact with the external environment, while the latter uses the FG signal line circuit to provide feedback on motor operation information.

[0062] For the different types of motor controllers mentioned above, during long-term reliability testing and monitoring, it is necessary to periodically adjust the motor operating speed to operate under different conditions, and monitor and record various parameters such as operating speed, bus voltage, output power, output phase voltage, and fault information under these conditions. Therefore, the following approach is adopted: Figure 1 The provided motor operation monitoring system enables the analysis and monitoring of different types of motor controllers.

[0063] The system comprises the following components: The host computer initializes and configures the parameters of the target controller and monitor, and sends periodic motor operation control commands and motor operation query commands to the initialized controller and monitor. The controller and monitor acquire motor operation parameters through the motor controller, packages the motor operation parameters and initialization configuration parameters according to a preset data structure, uploads them to the data receiving and processing terminal, and sends the periodic motor operation control commands and motor operation query commands from the host computer to the motor controller. The motor controller controls the motor to operate under preset conditions according to the motor operation control commands and feeds back the corresponding query parameters to the controller and monitor according to the motor operation query commands. The data receiving and processing terminal performs differentiated analysis and processing on the motors based on the data packets packaged by the controller and monitor, tailored to different motor types.

[0064] The aforementioned digital controller and detector are controlled by digital commands, namely communication control commands. The controller and detector interact with the motor controller through communication, thereby achieving precise control of motor speed, output torque, etc.

[0065] Specifically, the flowchart of the motor operation monitoring method is as follows: Figure 3 As shown, the specific process includes:

[0066] Step S301: The communication harness of the controller and monitor is connected to the motor controller, that is, the motor controller is connected to the controller and monitor via a signal line or a communication line.

[0067] Step S302, Controller and Monitor Configuration Initialization: The host computer initializes the parameters of the controller and monitor.

[0068] Step S303, Periodic command control and command query: The host computer sends periodic motor operation control commands and motor operation query commands to the controller and monitor.

[0069] Step S304, Real-time Packaging and Uploading of Specific JSON Data Structure to the Server: The controller and monitor obtain motor operating parameters through the motor controller, and then pack the motor operating parameters and initialization configuration parameters into a preset data structure and upload them to the cloud server and / or local server.

[0070] Step S305: The system schedules data receiving and processing terminal data and performs motor operation status analysis.

[0071] In one optional implementation, the host computer is also used to access the target address of the target controller and monitor via a local address or a unique ID, and to perform parameter initialization configuration of the target controller and monitor based on the target address.

[0072] A flowchart illustrating the method for initializing and configuring parameters for the controller and monitor by the host computer is shown below. Figure 4 As shown, the specific process includes:

[0073] Step S401: The host computer obtains the target address of the controller and monitor.

[0074] In step S402, the host computer accesses the target address of the controller and monitor through either a local address or a 24-bit unique ID.

[0075] In step S403, the host computer configures the controller and monitor with information such as its uplink and downlink serial port parameters, the type of motor to be monitored, and whether to clear historical data. When deciding whether to clear historical data, it is necessary to determine whether a motor operation control command is required.

[0076] In one optional implementation, step S403 includes:

[0077] Step a1: When a motor operation control command is required, the motor operation control command sequence and the motor operation query command are obtained sequentially, and it is determined whether to clear the historical data of the equipment. If yes, the historical data of the equipment is cleared and the verification code is obtained; otherwise, the verification code is obtained directly.

[0078] Step a2: When motor operation control commands are not needed, obtain motor operation query commands and determine whether to clear the equipment historical data. If yes, clear the equipment historical data and obtain the verification code; otherwise, directly obtain the verification code.

[0079] It should be noted that the aforementioned checksum is a string of characteristic values ​​generated by the controller and monitor after processing historical data clearing operations or completing initial configuration for data integrity verification. It is typically calculated using a specific algorithm (such as CRC cyclic redundancy check) based on the device's current status data or configuration information. The function of the checksum is as follows:

[0080] 1. Data Integrity Verification: The checksum is packaged together with motor operating data, configuration parameters, etc., and transmitted to the server. The server recalculates the checksum value of the data and compares it with the received checksum. This allows for quick determination of whether the data has been tampered with or lost during transmission due to link interference, equipment failure, or other reasons, ensuring the accuracy of the received data. For example, after historical data is cleared, the checksum is generated based on this cleared state. The cloud server or local server can use the checksum to confirm that the historical data clearing operation has been effectively performed.

[0081] 2. Status Consistency Confirmation: The checksum serves as a digital fingerprint of the controller and monitor's configuration status. After the host computer issues a command to clear historical data, the controller and monitor execute the operation and generate a new checksum. The host computer or server can confirm whether the device has completed the historical data clearing by checking the change in the checksum, thus avoiding configuration inconsistencies caused by command transmission delays or device non-response.

[0082] 3. Link Reliability Guarantee: Combined with a two-way data length verification mechanism, the checksum further enhances the anti-interference capability of data transmission. Even if some data is corrupted during transmission, a mismatch in the checksum can promptly trigger data retransmission or anomaly alarm, ensuring the stability of the data link during long-term reliability testing.

[0083] Setting an option to clear historical data when configuring the controller and monitor aims to ensure the accuracy of the initial configuration, avoid interference from historical data, and guarantee the continuity and effectiveness of data monitoring.

[0084] Step a3: Set the motor operating speed sequence and the query sequence of the required motor operating data according to the predetermined operating conditions in the motor operation control command, and send the above data to the controller and monitor to complete the configuration initialization.

[0085] After the controller and monitor complete the initial configuration, periodic motor operation control commands and query commands can be sent to the controller and monitor. The real-time motor operation status data is packaged according to a unique JSON data structure and uploaded to the data receiving and processing terminal (cloud server and / or local server) via wired or wireless means. The system then calls the server data for AI data analysis to obtain the status of the motor throughout the entire operation cycle.

[0086] In one optional implementation, the host computer is also used to issue periodic motor operation control commands and motor operation query commands in a cross-transmission manner.

[0087] Specifically, such as Figure 5 As shown in the diagram, the motor operation control command and motor operation query command cross-sequence are optimized by cross-sending periodic motor operation control commands and query commands to ensure that control commands and query commands do not conflict with each other at the same time. After receiving the control command, the motor controller will drive the motor to operate at the predetermined speed and torque conditions according to the control command, and respond to the query command.

[0088] In one optional implementation, the motor operating parameters include input voltage command, output power command, output torque command, operating speed command, cumulative start-stop count, and cumulative running time; the initialization configuration parameters include the type of motor to be monitored, uplink and downlink communication configuration parameters, and a checksum obtained by clearing historical data of the device; the controller and monitor are also used to package the input voltage command, output power command, output torque command, operating speed command, cumulative start-stop count, cumulative running time, type of motor to be monitored, uplink and downlink communication configuration parameters, checksum, local area address, and unique ID according to a preset data structure.

[0089] Specifically, the preset data structure in this embodiment is a JSON data structure.

[0090] The controller and monitor continuously acquire real-time operating data of the motor via communication or signal lines, such as input voltage commands, output power commands, output torque commands, operating speed commands, and indirect data like the cumulative number of starts and stops and cumulative operating time, inferred from feedback operating speed information. When the server accesses data, the controller and monitor combine the above motor data, the type of motor to be monitored, uplink and downlink communication configuration parameters, checksum data, and other data, along with the local area address and 24-bit unique ID used by the host computer when accessing the controller and monitor's target address, into a specific JSON data structure network packet. A schematic diagram of the JSON data structure network packet composition is shown below. Figure 6 As shown.

[0091] For example, taking the company's mainstream products, BD, DM3, and 485 series motors, as examples, the configuration frame obtained by the host computer for parameter initialization configuration of the controller and monitor is explained. Among them, the BD motor uses the FG signal as the motor controller output, the BD motor uses the RT communication circuit as the motor controller output (simplex), and the 485 motor uses the RS-485 standard circuit as the motor controller output. The host computer sends the configuration frame to the controller and monitor in a JSON data structure. The configuration frame code is as follows: {“operate”:“01”,“address”:“03”,“id”:“2033365839315005008A00A2”,“motortype”:“03”,“usart”:“9o1”,“baud”:“009600”,“poll28”:[“81040C0300001C9A”,“81040C010000BD5A”],“frequency”:“07”,“set08”:[],“interval”:“20”,“clear”:“00”,“crc”:“9A4E”}.

[0092] Parsing of each field in the above configuration frame:

[0093] operate: Operation command identifier, "01" represents a certain preset operation type (such as control command, query command, etc., the specific function needs to be determined in combination with the system protocol).

[0094] address: Address information, "03" is the device address, etc., used to identify a specific device (target address of the controller and monitor) in a multi-device network.

[0095] ID: Unique identification code for the device. "2033365839315005008A00A2" is the unique ID of the controller and monitor, used to distinguish different devices.

[0096] motortype: Motor type. "0" is an encoded value that needs to be checked against the system dictionary table. It may represent a specific motor type such as asynchronous motor or synchronous motor.

[0097] usart: Related to serial port parameters. "901" is a simplified encoding for serial port configuration (such as a combination encoding that includes information such as baud rate, data bits, stop bits, and parity bits).

[0098] baud: baud rate, "009600" indicates that the serial communication baud rate is 9600.

[0099] poll28: An array containing multiple sub-data, namely ["81040C0300001C9A", "81040C010000BD5A"]. These two long strings are the motor operation parameter frame and configuration frame.

[0100] frequency is related to frequency, and 07 represents the frequency value or code.

[0101] "set08" is the set value, and "1" is the target frequency, speed, and other set parameters.

[0102] The `clear` command, with "1" indicating a "clear history data" operation.

[0103] After the host computer completes the initialization configuration of the controller and monitor parameters, the controller and monitor obtain the configuration frame and the motor operating parameters. It then packages the motor operating parameters and the initialization configuration parameters into a JSON data structure to obtain a JSON data structure network packet, which is uploaded to the data receiving and processing terminal. The JSON data structure network packet is represented as an upload frame, as shown below:

[0104] {"address":"03","device_id":"2033365839315005008A00A2","motortype":"03","485_zl":["81040C030741DE" ,"81040C010BB4BA"],"485_qdcs":"0000097E","485_tzcs":"0000097A","485_yxsj":"0000328F","crc":"6AD5"}.

[0105] Parsing of each field in the above uploaded frame:

[0106] address: "03" Device address: Identifier used to locate the target device in a multi-device network (target address of the controller and monitor).

[0107] device_id: "2033365839315005008A00A2" Unique device ID: The unique identifier of the controller and monitor.

[0108] motortype "03" Motor type code: "03" is a predefined code value of the system (it needs to be checked against the system dictionary table to correspond to specific types such as "three-phase asynchronous motor with RS-485 communication", which is used for server differentiation analysis).

[0109] 485_zl["81040C030741DE","81040C010BB4BA"] RS-485 Command / Status Frame: "485" indicates RS-485 communication, and "zl" is an abbreviation for "command" or "status quantity"; the two long strings are the raw data frames transmitted on the RS-485 bus (containing real-time motor operating parameters such as voltage and current, or status codes of controller response commands), and the specific content needs to be parsed through the RS-485 protocol.

[0110] 485_qdcs"0000097E" represents the cumulative number of starts via RS-485: "qdcs" is the number of starts, and the field value is a hexadecimal number, which is 2430 when converted to decimal, representing the cumulative number of motor starts obtained through RS-485.

[0111] 485_tzcs"0000097A" represents the cumulative number of stops via RS-485. The hexadecimal value 0000097A is converted to decimal as 2426, which represents the cumulative number of motor stops obtained through RS-485.

[0112] 485_yxsj"0000328F" represents the cumulative running time via RS-485. The hexadecimal value 0000328F is 12943 in decimal, which means the cumulative running time of the motor obtained through RS-485.

[0113] "crc"6AD5" is the CRC checksum, or Cyclic Redundancy Check value, used to verify the integrity of the entire JSON data during transmission. After receiving the data, the server recalculates the CRC value; if it matches this field, it confirms that the data has not been tampered with or damaged by interference.

[0114] The types of motors to be monitored are set by the host computer and fed back by the controller and monitor so that the cloud server or local server can receive the JSON data structure network packets and perform differentiated data processing according to the motor type.

[0115] To address the issue of data interference during transmission, a two-way verification process is implemented between the total length of transmitted data and the server to ensure that the data received by the server is free from contamination.

[0116] The JSON data structure network packet is transmitted wirelessly to the cloud or wired to the local server for secondary analysis, outlining the motor's operating status throughout the long-term reliability test or short-term observation phase, allowing designers to monitor and analyze the motor's operating status and lifespan information in real time.

[0117] In an optional implementation, this embodiment also provides a motor operation monitoring system for monitoring multiple motors that are close to each other in the same area, as shown in the schematic diagram below. Figure 7 As shown, the system also includes: at least two motor controllers, a master controller and monitor, and at least two slave controllers and monitors; the master controller and monitor includes a wireless routing module; each motor controller is communicatively connected to a controller and monitor; at least two slave controllers and monitors are connected in parallel to the wireless routing module; the master controller and monitor is used to forward its own data and the data of each slave controller and monitor to a cloud server and / or a local server.

[0118] Specifically, the motor operation monitoring system consists of a master controller and monitor and multiple slave controllers and monitors. The slave controllers and monitors are connected in parallel to the wireless routing module of the master controller and monitor. The uplink wireless router of the master controller and monitor is responsible for forwarding data from the master and slave controllers and monitors to the server.

[0119] As described above, the motor operation monitoring system adopts a distributed networking architecture with one master and multiple slaves. The master controller and monitor acts as the core node, integrating a wireless routing module with data forwarding capabilities (supporting wireless transmission protocols such as 4G and WIFI). Multiple slave controllers and monitors are connected in parallel to this wireless routing module through standardized interfaces (such as wireless RF interfaces or Ethernet interfaces), forming a star-shaped data transmission network. This structure eliminates the need for a separate server connection module for each slave controller and monitor, reducing hardware costs and wiring complexity, and is particularly suitable for scenarios where motors are deployed in a dispersed manner. The cloud server and local server can receive data from all devices through a single link, reducing server interface usage and facilitating unified data storage, analysis, and traceability. The multi-link connection design between the master device and the servers (cloud server and local server) reduces the risk of data transmission interruption due to single-point failures, ensuring the data integrity of long-term reliability tests.

[0120] This embodiment provides a motor operation monitoring system, which can serve as a solution for overall reliability monitoring or on-site application monitoring of motors and motor controllers. This monitoring solution boasts strong real-time performance, does not rely on complex and costly photoelectric sensors, is easy to implement, and is compatible with different communication protocols for configurable operation, exhibiting strong versatility. The system transmits motor operation data to a server, which only needs to perform high-performance data processing, analysis, and data storage. The system places low demands on the computational performance of individual controllers and monitors, significantly reducing server resource pressure. Furthermore, the system can offload highly repetitive and real-time access operations to the controllers and monitors, effectively reducing server resource overhead during large-scale applications.

[0121] This embodiment provides a motor operation monitoring method, which can be used in the aforementioned motor operation monitoring system. Figure 8 This is a flowchart of a motor operation monitoring method according to an embodiment of the present invention, such as... Figure 8 As shown, the process includes the following steps:

[0122] Step S801: The host computer initializes and configures the parameters of the target controller and monitor, and sends periodic motor operation control commands and motor operation query commands to the target controller and monitor after the initialization and configuration are completed.

[0123] In step S802, the controller and monitor acquire motor operating parameters through the motor controller, and upload the motor operating parameters and initialization configuration parameters to the data receiving and processing terminal after packaging the data according to the preset data structure. The controller also sends the periodic motor operation control commands and motor operation query commands issued by the host computer to the motor controller.

[0124] In step S803, the motor controller controls the motor body to operate under preset conditions according to the motor operation control command, and feeds back the corresponding query parameters to the controller and monitor according to the motor operation query command.

[0125] Step S804: The data receiving and processing terminal uses data packets packaged from the controller and monitor to perform differentiated analysis and processing on motors of different types.

[0126] Further details of each of the above steps are the same as those in the corresponding embodiments described above, and will not be repeated here.

[0127] This embodiment also provides a motor operation monitoring device, which is used to implement the above embodiments and preferred embodiments; details already described will not be repeated. As used below, the term "module" can refer to a combination of software and / or hardware that implements a predetermined function. Although the device described in the following embodiments is preferably implemented in software, hardware implementation, or a combination of software and hardware, is also possible and contemplated.

[0128] This embodiment provides a motor operation monitoring device, which is applied to a motor operation monitoring system, such as... Figure 9 As shown, it includes:

[0129] The initialization configuration and command issuance module 901 is used to initialize the parameters of the target controller and monitor using a host computer, and to issue periodic motor operation control commands and motor operation query commands to the target controller and monitor after the initialization configuration is completed.

[0130] The data packaging and instruction sending module 902 is used to obtain motor operating parameters through the motor controller using the controller and monitor, package the motor operating parameters and initialization configuration parameters according to the preset data structure and upload them to the data receiving and processing terminal, and send the periodic motor operation control instructions and motor operation query instructions issued by the host computer to the motor controller.

[0131] The motor control module 903 is used to control the motor body to operate under preset conditions according to the motor operation control command, and to feed back the corresponding query parameters to the controller and monitor according to the motor operation query command.

[0132] The differentiation processing module 904 is used to perform differentiated analysis and processing on motors based on different motor types by using data packets packaged by the data receiving and processing terminal based on the controller and monitor. Further functional descriptions of the above modules and units are the same as in the corresponding embodiments described above, and will not be repeated here.

[0133] In this embodiment, the motor operation monitoring device is presented in the form of a functional unit. Here, a unit refers to an ASIC (Application Specific Integrated Circuit) circuit, a processor and memory that execute one or more software or fixed programs, and / or other devices that can provide the above functions.

[0134] This invention also provides a computer device having the above-described features. Figure 9 The motor operation monitoring device shown.

[0135] Please see Figure 10 , Figure 10 This is a schematic diagram of the structure of a computer device provided in an optional embodiment of the present invention, such as... Figure 10 As shown, the computer device includes one or more processors 10, memory 20, and interfaces for connecting the components, including high-speed interfaces and low-speed interfaces. The components communicate with each other via different buses and can be mounted on a common motherboard or otherwise installed as needed. The processors can process instructions executed within the computer device, including instructions stored in or on memory to display graphical information of a GUI on external input / output devices (such as display devices coupled to the interfaces). In some alternative implementations, multiple processors and / or multiple buses can be used with multiple memories and multiple memory modules, if desired. Similarly, multiple computer devices can be connected, each providing some of the necessary operations (e.g., as a server array, a group of blade servers, or a multiprocessor system). Figure 10 Take a processor 10 as an example.

[0136] Processor 10 may be a central processing unit, a network processor, or a combination thereof. Processor 10 may further include a hardware chip. The hardware chip may be an application-specific integrated circuit (ASIC), a programmable logic device (PLD), or a combination thereof. The programmable logic device may be a complex programmable logic device (CAMP), a field-programmable gate array (FPGA), a general-purpose array logic (GDA), or any combination thereof.

[0137] The memory 20 stores instructions executable by at least one processor 10 to cause the at least one processor 10 to perform the method shown in the above embodiments.

[0138] The memory 20 may include a program storage area and a data storage area. The program storage area may store the operating system and applications required for at least one function; the data storage area may store data created based on the use of the computer device. Furthermore, the memory 20 may include high-speed random access memory and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some alternative embodiments, the memory 20 may optionally include memory remotely located relative to the processor 10, and these remote memories may be connected to the computer device via a network. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof.

[0139] The memory 20 may include volatile memory, such as random access memory; the memory may also include non-volatile memory, such as flash memory, hard disk or solid-state drive; the memory 20 may also include a combination of the above types of memory.

[0140] The computer device also includes an input device 30 and an output device 40. The processor 10, memory 20, input device 30, and output device 40 can be connected via a bus or other means. Figure 10 Taking the example of a connection between China and Israel via a bus.

[0141] Input device 30 can receive input numerical or character information, and generate key signal inputs related to user settings and function control of the computer device, such as a touchscreen, keypad, mouse, trackpad, touchpad, joystick, one or more mouse buttons, trackball, joystick, etc. Output device 40 may include display devices, auxiliary lighting devices (e.g., LEDs), and haptic feedback devices (e.g., vibration motors). The aforementioned display devices include, but are not limited to, liquid crystal displays, light-emitting diodes, displays, and plasma displays. In some alternative embodiments, the display device may be a touchscreen.

[0142] This invention also provides a computer-readable storage medium. The methods described above according to embodiments of the invention can be implemented in hardware or firmware, or implemented as computer code that can be recorded on a storage medium, or implemented as computer code downloaded via a network and originally stored on a remote storage medium or a non-transitory machine-readable storage medium and then stored on a local storage medium. Thus, the methods described herein can be processed by software stored on a storage medium using a general-purpose computer, a dedicated processor, or programmable or dedicated hardware. The storage medium can be a magnetic disk, optical disk, read-only memory, random access memory, flash memory, hard disk, or solid-state drive, etc.; further, the storage medium can also include combinations of the above types of memory. It is understood that computers, processors, microprocessor controllers, or programmable hardware include storage components capable of storing or receiving software or computer code, which, when accessed and executed by the computer, processor, or hardware, implements the methods shown in the above embodiments.

[0143] A portion of this invention can be applied as a computer program product, such as computer program instructions, which, when executed by a computer, can invoke or provide the methods and / or technical solutions according to the invention through the operation of the computer. Those skilled in the art will understand that the forms in which computer program instructions exist in a computer-readable medium include, but are not limited to, source files, executable files, installation package files, etc. Correspondingly, the ways in which computer program instructions are executed by a computer include, but are not limited to: the computer directly executing the instructions, or the computer compiling the instructions and then executing the corresponding compiled program, or the computer reading and executing the instructions, or the computer reading and installing the instructions and then executing the corresponding installed program. Here, the computer-readable medium can be any available computer-readable storage medium or communication medium accessible to a computer.

[0144] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A motor operation monitoring system characterized by comprising: The system comprises: a host computer, at least one motor controller, at least one control and monitor, and a data receiving and processing terminal; the control and monitor is in communication connection with the motor controller, and the data receiving and processing terminal is connected with the control and monitor; the host computer is used for parameter initialization configuration of a target control and monitor, and periodic motor operation control instructions and motor operation query instructions are issued to the target control and monitor after initialization configuration is completed; the control and monitor is used for obtaining motor operation parameters through the motor controller, and the motor operation parameters and initialization configuration parameters are data packed according to a preset data structure and uploaded to the data receiving and processing terminal, and the periodic motor operation control instructions and motor operation query instructions issued by the host computer are sent to the motor controller; the motor controller is used for controlling the motor body to run in a preset working condition according to the motor operation control instructions, and feeding back corresponding query parameters to the control and monitor according to the motor operation query instructions; the data receiving and processing terminal is used for differential analysis and processing of motors for different motor types based on data packets data packed by the control and monitor.

2. The system of claim 1, wherein, The host computer is also used for accessing a target address of a target control and monitor through a local address or an independent unique ID mode, and performing parameter initialization configuration of the target control and monitor based on the target address.

3. The system of claim 1, wherein, The host computer is also used for issuing the periodic motor operation control instructions and the motor operation query instructions in a cross sending form.

4. The system of claim 2, wherein, The motor operation parameters include input voltage instructions, output power instructions, output torque instructions, running speed instructions, cumulative start-stop times, and cumulative running times; the initialization configuration parameters include a to-be-monitored motor type, uplink and downlink communication configuration parameters, and a verification code obtained by clearing historical data of the equipment; The control and monitor is also used for data packing of the input voltage instructions, the output power instructions, the output torque instructions, the running speed instructions, the cumulative start-stop times, the cumulative running times, the to-be-monitored motor type, the uplink and downlink communication configuration parameters, the verification code, the local address, and the independent unique ID according to a preset data structure.

5. The system of claim 4, wherein, The data receiving and processing terminal comprises a cloud server and a local server, the cloud server is connected with the control and monitor through a wireless mode, and the local server is connected with the control and monitor through a wireless mode or a wired mode.

6. The system of claim 5, wherein, The system further comprises at least two motor controllers, one master control and monitor, and at least two slave control and monitors; the master control and monitor comprises a wireless routing module; each motor controller is in communication connection with one control and monitor; the at least two slave control and monitors are mounted to the wireless routing module in a parallel mode; the master control and monitor is used for forwarding data of itself and each slave control and monitor to a cloud server and / or a local server.

7. A method of monitoring operation of an electric machine, characterized by, The method is applied to the motor operation monitoring system in any one of claims 1 to 6, and the method comprises: The host computer initializes and configures parameters of the target control and monitor, and issues periodic motor operation control instructions and motor operation query instructions to the target control and monitor after the initialization and configuration are completed. The control and monitor obtain motor operation parameters through the motor controller, and uploads the motor operation parameters and the initialization configuration parameters to the data receiving and processing terminal after data packaging according to a preset data structure, and sends the periodic motor operation control instructions and the motor operation query instructions issued by the host computer to the motor controller. The motor controller controls the motor body to operate in a preset working condition according to the motor operation control instructions, and feeds back corresponding query parameters to the control and monitor according to the motor operation query instructions. The data receiving and processing terminal performs differential analysis and processing on the motor according to different motor types based on the data packets packaged by the control and monitor.

8. An electric machine operation monitoring device, characterized by The device is applied to the motor operation monitoring system in any one of claims 1 to 6, and comprises: An initialization configuration and instruction issuing module, which is configured to initialize and configure parameters of the target control and monitor by using the host computer, and issue periodic motor operation control instructions and motor operation query instructions to the target control and monitor after the initialization and configuration are completed. A data packaging and instruction sending module, which is configured to obtain motor operation parameters by the control and monitor through the motor controller, and upload the motor operation parameters and the initialization configuration parameters to the data receiving and processing terminal after data packaging according to a preset data structure, and send the periodic motor operation control instructions and the motor operation query instructions issued by the host computer to the motor controller. A motor control module, which is configured to control the motor body to operate in a preset working condition according to the motor operation control instructions by using the motor controller, and feed back corresponding query parameters to the control and monitor according to the motor operation query instructions. A differential processing module, which is configured to perform differential analysis and processing on the motor according to different motor types based on the data packets packaged by the control and monitor.

9. A computer device, comprising: Comprise: A memory and a processor, which are communicatively connected, and the memory stores computer instructions, and the processor executes the computer instructions to perform the motor operation monitoring method in claim 7.

10. A computer-readable storage medium, characterized in that, The computer readable storage medium stores computer instructions, and the computer instructions are used to make the computer execute the motor operation monitoring method in claim 7.

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