Fault early warning management system of floor type centrifugal machine

Abstract

The invention relates to the technical field of laboratory asset informatization management data processing, and discloses a floor type centrifugal machine fault early warning management system which comprises a data communication interface, a settlement rule database and a central settlement audit processor. And calling a nonlinear depreciation multiplier mapping table to convert the index into an asset consumption exchange rate, performing weighted conversion on the operation duration by using the exchange rate to generate a standard asset consumption equivalent, and deducting the equipment life cycle debit account balance. The problem of data distortion caused by a traditional linear depreciation model is solved, and dynamic accurate settlement and compliance quantitative auditing of asset values are achieved.

Description

Technical Field

[0001] This invention relates to a fault early warning management system for floor-standing centrifuges, belonging to the field of laboratory asset information management data processing technology. Background Technology

[0002] In the current management system of large-scale biomedical and clinical testing laboratories, the lifecycle management of electromechanical assets of floor-standing centrifuges generally adopts a digital ledger model based on the laboratory information management system. This model reads equipment operation logs through network interfaces and uses calendar cycles or cumulative physical runtime as the core audit dimension to perform administrative management functions such as asset depreciation calculation, maintenance plan generation, and utilization rate statistics.

[0003] However, when the aforementioned linear time-dimensional management model is applied to equipment like centrifuges, which have high rotational inertia and high mechanical stress, inherent data logic defects become apparent. The physical wear process of centrifuges exhibits nonlinear characteristics. Even minor deviations in sample balancing, insufficient rotor locking torque, or early lubrication deterioration of the transmission shaft, while not triggering the electrical fault shutdown threshold of the motor drive unit and preventing additional mechanical damping work during equipment operation, can leave the system under implicit high-stress conditions. To address these physical risks, the industry has developed monitoring solutions based on dynamic models. For example, Chinese invention patent CN116493144B discloses a fault early warning method, device, and equipment for centrifuges. This method models the discretized rotor system of the centrifuge, determines and corrects the rotor system's motion equations, and utilizes a neural network fault prediction model to achieve online monitoring of potential centrifuge faults. While control and trend analysis address the issue of reactive maintenance that inevitably leads to downtime due to malfunctions, existing technologies focus on physical safety threshold determination and whether equipment experiences functional failure or downtime risk. They fail to address the economic evaluation of assets under sub-optimal operating conditions. They cannot transform high-damping operating behaviors, such as sample balancing deviations and rough start-stops that do not trigger alarm thresholds, into intuitive asset depreciation and billing indicators. Existing management data processing methods assume that unit operating time is equivalent to asset depreciation weight, failing to perceive and quantify the gray, high-energy-consuming state between normal operation and malfunction downtime. This results in a severe disconnect between the remaining book value in the management system and the remaining physical lifespan of the equipment. The distorted asset value data not only makes spare parts budget preparation lack accurate data support but also prevents management departments from establishing objective quantitative audit and accountability mechanisms for operators' long-term non-standard balancing or rough use.

[0004] Therefore, the technical problem to be solved by this invention is how to extract data reflecting the mechanical damping state characteristics from equipment operation logs, transform it into quantitative asset hidden loss management indicators, and solve the problems of distorted asset value assessment and lack of auditing of illegal operations in the existing management system. Summary of the Invention

[0005] To address the problems mentioned in the background art, the technical solution of the present invention is as follows: a fault early warning management system for floor-standing centrifuges, which is deployed on a laboratory asset information management server and includes a data communication interface, a settlement rule database, and a central settlement audit processor.

[0006] The data communication interface is used to periodically poll centrifuge devices within the local area network to obtain an operation log data stream containing the set speed, steady-state running time, and actual acceleration time.

[0007] The settlement rules database is used to store the theoretical benchmark speed-up time of each model of centrifuge and the preset nonlinear depreciation multiplier mapping table, and defines the one-way function mapping relationship between the speed-up hysteresis index as a physical state quantity and the asset consumption exchange rate as a management metric.

[0008] The central settlement and audit processor is used to execute the dynamic settlement process of asset value, including: retrieving the corresponding theoretical benchmark acceleration time based on the set rotation speed, calculating the time domain deviation of the actual acceleration time relative to the theoretical benchmark acceleration time to generate an acceleration hysteresis index characterizing the mechanical damping state of the equipment; calling the nonlinear depreciation multiplier mapping table to map the acceleration hysteresis index to a dimensionless asset consumption exchange rate; using the asset consumption exchange rate to perform a weighted conversion on the steady-state running time to calculate the standard asset consumption equivalent for a single running task; and accessing the equipment's full life cycle debit account in the settlement rules database, deducting the standard asset consumption equivalent from the current account balance, and generating an asset disposal instruction when the account balance reaches a preset administrative management threshold.

[0009] Preferably, the nonlinear depreciation multiplier mapping table includes a segmented penalty rule based on the compliance tolerance range: when the acceleration hysteresis index is within the preset compliance tolerance range, the asset consumption exchange rate is locked at the base unit value; when the acceleration hysteresis index exceeds the compliance tolerance range but does not reach the blocking threshold, the asset consumption exchange rate increases exponentially and nonlinearly with the increase of the acceleration hysteresis index, so as to generate a loss value with an amplification factor relative to the physical condition deterioration in the management account.

[0010] Preferably, when calculating the standard asset consumption equivalent, the central settlement audit processor also introduces a fixed cost variable based on start-stop actions, transforms mechanical fatigue in the non-steady-state process into a fixed deduction amount for a single audit, and adds this fixed deduction amount to the runtime after the asset consumption exchange rate weighting to form the standard asset consumption equivalent.

[0011] Preferably, the central settlement audit processor calculates the standard asset consumption equivalent based on the following formula: ,in, Standard asset consumption equivalent. For steady-state operation time, The asset consumption exchange rate determined by the lag index. This is a fixed audit cost constant preset based on a single start / stop action.

[0012] Preferably, the central settlement audit processor is also used to perform a physical logic self-consistency verification process for the input data, including: constructing a theoretical speed-up response range model based on the characteristics of the motor drive; comparing the actual speed-up time with the theoretical speed-up response range model; if the actual speed-up time is lower than the lower limit of the theoretical speed-up response range model, generating an audit anomaly flag indicating that the rotor load registration data is inaccurate; if the actual speed-up time is higher than the upper limit of the theoretical speed-up response range model, generating an asset aging flag indicating that the transmission system efficiency is deteriorating.

[0013] Preferably, the central settlement audit processor also includes a compliance credit audit module, which is used to calculate the difference between the standard asset consumption equivalent and the steady-state operating time, define the difference as the loss amount of the violation operation and record it in the compliance credit file of the corresponding operation user; and calculate the cumulative value of the compliance credit file within a specific time window. When the cumulative value exceeds the preset credit red line, an operation compliance audit report for the user is generated.

[0014] Preferably, the system also includes a risk trend prediction module, which is used to calculate the growth rate of the acceleration hysteresis index over multiple consecutive operating cycles, construct a time series model that reflects the evolution trend of the equipment's mechanical damping, extrapolate the expected calendar time when the equipment's full life cycle debit account balance drops to zero based on the time series model, and dynamically adjust the generation sequence of the spare parts procurement plan according to the expected calendar time.

[0015] Preferably, the asset disposal instruction includes writing a logical lock flag to the centrifuge control register, which is used to freeze the reservation and usage rights of the device at the information management level until an account reset authorization instruction is received from the administrator.

[0016] Preferably, the system is also equipped with a data cleaning module, which is used to identify interruption event records containing error codes in the operation log, extract the transient data at the moment the interruption event occurs and mark it as an emergency stop impact loss record, and call a preset accident penalty algorithm to calculate the additional asset consumption equivalent corresponding to the emergency stop impact loss record and directly record it into the equipment's full life cycle debit account.

[0017] Preferably, the data communication interface is also used to acquire the centrifuge imbalance monitoring value, and the central settlement audit processor is used to convert the imbalance monitoring value into an operation quality correction coefficient using a preset quality image model, and use the operation quality correction coefficient to perform a secondary weighted correction on the asset consumption exchange rate, so that the standard asset consumption equivalent includes a quantitative evaluation weight for the sample balance quality.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] 1. In the fault early warning of floor-standing centrifuges, a dynamic value conversion system based on the acceleration hysteresis characteristic is constructed to solve the problem of the disconnect between physical time and mechanical loss weight in traditional management. The system extracts the time domain response hysteresis generated by the motor overcoming damping work and converts it into a billing ratio reflecting the implicit loss of assets according to nonlinear mapping rules. The processing mechanism breaks the assumption of equivalence of unit running time and quantifies the extra mechanical stress of non-optimal working conditions into the value of asset debit account deduction. This ensures that the residual value of assets in the management database is dynamically anchored to the true physical health status of the equipment and eliminates the risk of depreciation data distortion.

[0020] 2. Utilizing damping hysteresis characteristics as audit evidence, a closed-loop digital performance evaluation system for personnel operation quality is constructed. Unlike traditional monitoring that only focuses on downtime due to malfunctions, the system captures and analyzes high-damping operation data caused by balancing deviations or insufficient rotor locking, converting it into an exponentially increasing asset consumption equivalent. This mechanism enables the management system to automatically identify long-term high-risk usage behaviors without manual intervention. An objective compliance credit file is generated through abnormal deductions from debit accounts, providing data-driven decision support for safety access and liability determination.

[0021] 3. By using an asset debit account system, the system transforms from static calendar planning to dynamic wear and tear tracking and maintenance decision-making. The system generates maintenance work orders based on the cumulative rate of fatigue index rather than simply the number of physical days. It identifies equipment nodes with low operating frequency but whose lifespan is rapidly declining due to long-term high-stress conditions. Based on the resource scheduling mechanism of the actual wear rate, it avoids over-maintenance of low-wear equipment and the failure of high-load equipment with potential damage. This enables the precise allocation of maintenance funds and spare parts resources to the actual demand points, improving the efficiency of laboratory asset lifecycle management. Attached Figure Description

[0022] Figure 1 This is a data processing flowchart for the system of the present invention to perform dynamic settlement and physical verification of asset value;

[0023] Figure 2 This is a schematic diagram illustrating the nonlinear response of the load imbalance on the acceleration hysteresis index according to the present invention.

[0024] Figure 3 This is a diagram showing the overall system topology and data interaction for closed-loop asset value management of the present invention. Detailed Implementation

[0025] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with specific implementation methods. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0026] This invention discloses a fault early warning management system for floor-standing centrifuges, consisting of a bottom-layer data acquisition layer, a middle-layer rule parsing layer, and a top-layer asset settlement layer. The core logic of the system operation lies in abandoning the traditional linear depreciation model based on physical calendar time and instead constructing a dynamic value settlement system based on the runtime response characteristics of the equipment. The workflow begins by periodically polling the equipment through a data communication interface to obtain a runtime log data stream containing timestamps. The central settlement and audit processor, based on a benchmark model preset in the settlement rule database, converts the physical-level acceleration response lag into the management-level asset consumption exchange rate, thereby calculating the standardized asset consumption equivalent and ultimately calculating the debit account balance for the entire life cycle of the equipment. Real-time deductions and audits are performed to achieve precise quantitative management and risk warning of laboratory asset value. In actual engineering deployments, facing the hidden high-stress operating conditions of centrifuges caused by minor rotor balancing errors, early deterioration of the lubrication system, or wear of the transmission shaft, the traditional management model that only relies on fault reporting has a lagging blind spot. To solve the problem of transforming non-homogeneous physical losses into unified management indicators, this invention's system is equipped with a dedicated data communication interface module. This module accesses the register addresses of each centrifuge controller at a preset polling frequency through a network protocol stack, reads and parses the real-time operation logs, and the parsed data stream is structured into discrete records containing specific fields. Each record includes at least the set rotation speed. Steady-state running time and actual acceleration time The actual acceleration time Defined as the time it takes for a motor to start from a standstill and until its speed stabilizes at the set speed. The time consumed within the ±1% error range is obtained by using the timer inside the system or by reading the timestamp difference from the device logs, and serves as the basis for subsequent asset audits.

[0027] To establish an objective audit benchmark, the system pre-sets theoretical benchmark ramp-up times for different models of centrifuges and rotor combinations in the settlement rules database. After receiving the log data from a single running task, the central settlement and audit processor executes a quantitative extraction process for time-domain hysteresis characteristics. The processor then uses the set rotational speed from the log data... The system retrieves the rotor model code and the corresponding theoretical reference acceleration time under standard no-load or rated load conditions from the database. The processor performs differential operations to calculate the actual boost time. relative to theoretical baseline acceleration time The time-domain deviation generates the acceleration hysteresis index. Its calculation logic is as follows: The acceleration lag index This system does not simply address physical errors, but rather uses digital audit indicators to characterize the damping state of a mechanical system. This damping state includes kinetic energy losses caused by unbalanced torques or frictional resistance. To address the issue of distorted asset value exchange rates due to neglecting differences in operating conditions in traditional management, the system introduces a nonlinear depreciation multiplier mapping table, stored in the settlement rule database, defining the physical state quantities... To manage the asset consumption exchange rate The processor calls this one-way function mapping table and performs calculations based on the obtained... The billing weight for the current task is determined, and this mapping logic includes segmented penalty rules based on compliance tolerance intervals: when When the situation is within the preset compliance tolerance range, the system determines the current operating condition to be in a standard state and adjusts the asset consumption exchange rate accordingly. Locked to a base unit value of 1.0, where this range is determined by the device's factory calibration data, for example, 0 seconds to 2.0 seconds; when When the system determines that the device is in a high-damping, non-optimal operating condition, it exceeds the compliance tolerance range but does not reach the blocking threshold. Follow The increase exhibits an exponential, non-linear growth, for example, following... The computational model, in which A preset penalty coefficient, such as 0.5, is used to generate a numerical loss value in the management accounts relative to the deterioration of physical operating conditions; when When the blocking threshold is reached or exceeded, a violation blocking flag is generated and will be displayed. Set to a preset extremely high value, such as 10.0, and trigger a shutdown interlocking process, where the blocking threshold is, for example, 5.0 seconds.

[0028] The construction of the nonlinear depreciation multiplier mapping table relies on destructive physical calibration tests conducted before the equipment leaves the factory. The calibration environment involves rigidly coupling the centrifuge drive shaft with a controllable magnetic powder brake, adjusting the brake's excitation current, and applying a gradient resistance torque of 0.5 N·m at the motor shaft end to simulate different mechanical damping conditions. Each level of resistance torque drives the motor to accelerate from rest to rated speed, and the acceleration hysteresis index is recorded simultaneously. The stator temperature rise rate and vibration energy spectral density were measured using thermocouples embedded in the stator windings and piezoelectric accelerometers attached to the bearing housings, respectively. Based on a material fatigue cumulative damage model, the processor defined accelerated loss zones as those where the temperature rise rate exceeded 120% of the baseline value or where vibration energy was concentrated in the asynchronous frequency band. The processor then normalized the physical damage gradient within these zones and fitted the data to generate... and The exponential function relationship curve, during the calibration process, directly anchors the depreciation rate to the physical measurement data of motor winding insulation aging and shaft fatigue wear, ensuring that the settlement parameters reflect the true physical lifespan consumption; the central settlement audit processor executes the acceleration hysteresis index. Real-time calculations are performed using a 5-length sliding median filter to preprocess the original speed sampling stream, eliminating transient spikes caused by electromagnetic interference, and retaining only the low-frequency trend term representing mechanical inertia to determine the actual acceleration time. The processor reads the 8-bit binary code fed back by the centrifuge rotor identification probe, and looks up the theoretical benchmark acceleration time under no-load standard air pressure for a specific rotor model in the settlement rule database. When the debit account balance drops to zero according to the formula, the system, without manual intervention, directly sends a hexadecimal lock command to the motor driver control register, lowers the PWM signal enable pin level, and the hardware-level cuts off the power supply to the motor's main circuit until a new reset authorization code is written to the encrypted interface, thus achieving a closed-loop protection based on physical state. After completing the exchange rate conversion, the central settlement and audit processor executes the core dynamic settlement process for asset value. To fully cover the combined consumption of asset lifespan by steady-state operation and transient start-stop, the processor introduces a fixed cost variable based on start-stop actions. This variable is a preset constant value used to quantify the fixed losses to assets caused by current surges and mechanical fatigue during motor start-up and shutdown. For example, each start-up and shutdown is equivalent to 50 standard consumption units. The processor calculates this value according to the formula... Calculate the standard asset consumption equivalent for a single running task. In this formula, This is the steady-state runtime of this mission. The system calculates the asset consumption exchange rate determined by the lag index. After calculation, it accesses the device's full lifecycle debit account in the database, reads the device's current account balance (i.e., the remaining asset value), and deducts the calculated value from that balance. .

[0029] To further enhance the logical consistency of the data and prevent data inaccuracies caused by user errors, the processor is also equipped with a physical logical consistency verification process. The system constructs a theoretical acceleration response range model based on the characteristics of motor drive, defining the upper and lower limits of acceleration time within the range allowed by physical laws, and extracting the actual acceleration time. Then, the processor compares it with the theoretical interval. If... If the load falls below the lower limit of the theoretical acceleration response range model, the system determines that the current record contains a physical paradox, generates an audit anomaly flag indicating that the rotor load registration data is inaccurate, and prompts the user that load information may have been underreported; if If the acceleration response range exceeds the upper limit of the theoretical acceleration response range model and mechanical failure factors are excluded, an asset aging marker indicating the performance degradation of the transmission system is generated, and this marker is stored as a correction factor in the equipment health record. In addition, the system also includes a compliance credit audit module to quantify the operational quality of personnel, and the processor calculates the standard asset consumption equivalent. With physical steady-state running time The difference between the two values ​​is defined as the loss caused by non-optimal operation and recorded in the compliance credit file of the corresponding user. The system calculates the cumulative value of this file within a specific time window. When the cumulative value exceeds the preset credit threshold, an operation compliance audit report is automatically generated for that user, providing laboratory managers with an objective basis for personnel performance evaluation. The risk trend prediction module uses time series analysis algorithms to calculate the acceleration hysteresis index. By constructing a model reflecting the evolution trend of equipment mechanical damping based on the growth rate over multiple consecutive operating cycles, the expected calendar time for the equipment's full lifecycle debit account balance to drop to zero is deduced. The generation sequence of spare parts procurement plans is dynamically adjusted to ensure that maintenance resources are in place in time before the asset value is exhausted. When the account balance reaches a preset administrative management threshold, such as when the remaining value is less than 10%, the central settlement audit processor generates an asset disposal instruction, including writing a logic lock flag to the centrifuge control register and freezing the reservation and usage rights of the equipment at the information management level until an account reset authorization instruction is received from the administrator.

[0030] Example 1: In the continuous operation scenario of a high-throughput biological sample processing center, floor-standing centrifuges are subjected to complex conditions of frequent start-stop cycles and non-constant loads. Minor deviations in sample balancing or early lubrication deterioration of transmission components are often insufficient to trigger the electrical fault shutdown threshold of the motor drive, but the equipment continues to perform work overcoming additional mechanical damping. Under such conditions, the fault early warning management system of this invention captures data in real time, including the set rotation speed, through a data communication interface. Steady-state running time and actual acceleration time The system analyzes the operation log data stream and uses data processing techniques to explicitly reveal hidden asset losses. When the central settlement audit processor detects the actual acceleration time of a certain task... Although it did not reach the hardware alarm limit, it was significantly higher than the theoretical benchmark ramp-up time corresponding to the settlement rule database. At that time, the processor does not perform an immediate electrical interruption, but instead uses a rise hysteresis index generated based on the difference. The weighted settlement process for asset value is initiated. During this process, the processor calls a pre-set nonlinear depreciation multiplier mapping table, which reflects the physical damping state. Mapped to an asset consumption exchange rate greater than the benchmark value of 1.0. For example, based on the mapping rules, a 2.5-second delay can be converted into a 1.5-fold billing weight, thereby establishing a non-linear relationship between physical delay characteristics and the rate of asset value loss at the management level.

[0031] In calculating the standard asset consumption equivalent of a single task At that time, through the formula Perform multi-dimensional value quantification, among which As fixed start-up and shutdown audit costs are added to the exchange rate-weighted runtime losses, this composite calculation mechanism ensures that, under the same physical operating time, the equipment under high-damping conditions will experience a faster deduction rate in its debit account balance throughout its entire lifecycle than equipment under standard operating conditions. This accurately maps the accelerated accumulation of mechanical fatigue onto the book value data. The system continuously monitors the rate of decline of this account balance, dynamically extrapolates the expected calendar time for the balance to reach zero using the risk trend prediction module, and automatically triggers spare parts procurement suggestions or asset disposal instructions when the account balance reaches a preset administrative threshold. This data-driven management model transforms the traditional passive maintenance strategy that relies on physical failures into predictive resource scheduling based on the rate of asset value consumption. This ensures that maintenance funds and spare parts resources can be accurately allocated based on the actual equipment health status and wear trends, while also providing quantitative data support for compliance and credit audits of operators.

[0032] Example 2: To objectively verify the technical effectiveness and engineering feasibility of the fault early warning management system of the present invention in a real industrial environment, a verification platform was built, including multiple floor-standing centrifuges and a central management server. This platform simulated typical continuous, high-load, and non-constant operating conditions in a high-throughput laboratory, aiming to verify the system's ability to quantify hidden asset losses and its early warning accuracy when facing actual operating noise and disturbances. The centrifuges used in the experiment were all industrial-grade devices with standard communication interfaces, a speed control accuracy of ±10 rpm, and a maximum speed of 20,000 rpm. The central management server was equipped with a high-performance processor capable of performing data acquisition and algorithm processing tasks in real time. During the experiment, Gaussian white noise with a signal-to-noise ratio of 20 dB and simulated 50 Hz power frequency interference harmonics were actively superimposed on the signal source to simulate the impact of the actual electromagnetic environment on data acquisition, ensuring that the verification results had a high degree of engineering realism.

[0033] In setting the experimental parameters, the selection of the sampling period followed a strict technical trade-off logic. Considering the constraints between the monitored signal, i.e., the spectral bandwidth of the speed change, and the system data processing load, to avoid signal aliasing under the Nyquist sampling theorem and ensure real-time performance, the sampling frequency was set to 10Hz, i.e., the sampling period was 0.1 seconds. This setting was based on the analysis of the dynamic characteristics of the centrifuge's acceleration process, ensuring that minute acceleration hysteresis characteristics could be captured without generating excessively redundant data streams. To comprehensively verify the technical effect, a multi-dimensional control system was designed, including the present invention's sample group and a partially missing control group (the nonlinear depreciation multiplier mapping table was removed) and an out-of-range control group (the acceleration hysteresis index exceeded the blocking threshold). By setting different gradients of load imbalance as the core problem variable, increasing in increments from 0g to 50g, a problem intensity gradient control system was constructed to reveal the intrinsic relationship between the technical effect and the severity of the problem. After the experiment started, each group of centrifuges executed a continuous start-stop cycle task according to the preset program. The system collected and recorded the set speed of each task in real time. Steady-state running time and actual acceleration time During the data processing phase, it was observed that the actual acceleration time increased with the increase of load imbalance. It exhibits a clear nonlinear growth trend, and this trend is partially masked in the original data with superimposed noise. After processing by the filtering and feature extraction algorithm built into the system of this invention, the noise is effectively suppressed, and the key acceleration hysteresis features are clearly revealed. Table 1 shows the comparison results of key intermediate feature data under different working conditions.

[0034] Table 1: Example table comparing key intermediate feature data

[0035]

[0036] Referring to Table 1, under standard equilibrium conditions, i.e., 0g imbalance, the acceleration hysteresis index of the sample group and the control group of this invention. Both are close to 0, and the exchange rate of asset consumption Maintaining a baseline value of 1.0 indicates that the system does not generate additional asset loss records under normal conditions. However, as the imbalance increases to 10g or more, the control group, lacking a nonlinear mapping mechanism, does not show a corresponding increase in recorded loss; while the sample group of this invention... Increase, and This then increases exponentially, for example, at a 30g imbalance level. Reaching 2.8 seconds, corresponding to The value has been increased to 1.8, accurately reflecting the accelerated wear and tear on equipment under high-damping conditions, especially when the imbalance reaches 50g in out-of-range conditions. Exceeding the 5.0-second blocking threshold, the system not only calculated an extremely high exchange rate but also correctly triggered the shutdown interlock logic, verifying the system's protection capability under extreme conditions. Further data shows that the standard asset consumption equivalent calculated by the sample group in this invention... There is a positive correlation between the imbalance and the value of the material, and the correlation exhibits a non-linear growth characteristic as expected, revealing the physical law of the impact of mechanical damping on asset life. In contrast, traditional statistical methods that rely solely on physical duration cannot distinguish the differences in wear under different operating conditions, leading to serious distortion in asset valuation.

[0037] Example 3: This example combines Figures 1 to 3 A description of a fault early warning management system for a floor-standing centrifuge, such as... Figure 1 As shown, the data processing flow begins with the physical entity of the floor-standing centrifuge generating raw data containing set speed, steady state, and acceleration duration. This data is then periodically polled and retrieved from the operation log via the data communication interface. In parallel, a physical logic self-consistency check based on the theoretical model of motor drive characteristics is performed to compare the actual acceleration response. The process then proceeds to the acceleration hysteresis index calculation stage, retrieving the theoretical benchmark acceleration time from the settlement rule database to calculate the time-domain deviation between the actual acceleration duration and the theoretical benchmark. Subsequently, based on the mapping rules, a nonlinear depreciation multiplier mapping table is called to complete the asset consumption exchange rate mapping. Combined with runtime weighting and start-up / stop fixed cost superposition, standard asset consumption equivalent settlement is performed. Simultaneously, audit data is sent to the compliance and credit audit module to generate a compliance file. Finally, account balance deduction and auditing are executed. When a threshold is reached, an asset disposal instruction is generated and the equipment's full lifecycle debit account balance is updated.

[0038] like Figure 2 As shown, this bar chart represents the acceleration hysteresis index under different load unbalances. (s) Changes, with the horizontal axis set to load imbalance in g, covering gradient test points from 0g baseline to 50g, and the vertical axis set to acceleration hysteresis index. (s) As the load imbalance increases progressively from 0g, the height of the corresponding black bars shows a non-linear upward trend, reflecting the increased time-domain response lag caused by the increase in physical damping, with the exponential value reaching its highest at 50g. Figure 3As shown, the overall logical structure of the system mainly consists of a floor-standing centrifuge cluster on the left, a central settlement and audit server in the middle, and a full lifecycle debit account on the right. The centrifuge cluster generates an operation log stream containing characteristics of acceleration hysteresis and mechanical damping and transmits it to the central settlement and audit server. This server, as the value conversion hub, executes the mapping logic of physical hysteresis-exchange rate amplification-value deduction, calculates the standard asset consumption equivalent, and outputs a deduction instruction to the full lifecycle debit account to store the remaining value balance. At the same time, the system sends a compliance audit report or balance warning information to the administrator decision terminal according to the account status, and has a reverse control loop that can feed back a shutdown lockout instruction to the centrifuge cluster under specific conditions.

[0039] Example 4: To address the safety hazards caused by the lack of quantitative auditing of minute changes in rotor load under traditional management models, this example details a systematic calibration procedure for rotor load compliance auditing. The core of this procedure is to establish an accurate rotor load-speed-response mapping model, thereby achieving logical self-consistency verification of user-reported data. On a standardized centrifuge testing platform, a specific model of fixed-angle rotor, such as R-12, is selected as the calibration object. Standard no-load conditions are set, i.e., no sample tubes are installed. The centrifuge is started, and the speed reached is recorded. For example, the actual acceleration time required to reach 10,000 rpm Gradient load experiments were conducted by symmetrically loading standard counterweights of different masses into the rotor to simulate various operating conditions ranging from 10% to 100% of the rated load. For each load gradient, the system performed three independent speed-up tests, and the average of the actual speed-up times was taken as the baseline response time under that load. .

[0040] By summarizing the above experimental data, the load-time characteristic curve of this rotor model was constructed. The least squares method was used to fit the experimental data points to obtain the characteristic acceleration time. With the total load mass of the rotor Empirical formula for the relationship between them: ,in, The load sensitivity coefficient is obtained through experimental calibration. The reference time for the no-load acceleration was measured. This includes correction terms for system errors and random disturbances. Based on this calibration model, the system executes real-time verification logic during actual operation. This is done when a user submits an operation request and registers the expected load quality via the management terminal. Then, the system automatically calculates the theoretical acceleration response range. ,in, based on The setting corresponds to 95% of the theoretical value, while Based on a 105% setting to accommodate reasonable engineering errors, the actual acceleration time monitored during actual operation... Below If the system determines there is a risk of false load reporting, such as the user's actual load being significantly less than the declared load or the rotor not being installed correctly, it will generate a logical anomaly flag and trigger the corresponding audit alert; conversely, if... Higher than If the signal is abnormal, it indicates that there may be overload or abnormal resistance in the transmission system. This procedure transforms the vague load management into a quantifiable physical verification, filling the audit blind spot in traditional management.

[0041] Example 5: To eliminate the impact of individual manufacturing differences in equipment and uncertainties in the physical model parameterization process on the accuracy of asset settlement, this example constructs an offline benchmark data filling and mapping table construction procedure deployed during the final inspection stage of equipment leaving the factory. The centrifuge to be calibrated is placed in a standard test environment with constant temperature and humidity and equipped with a zero dynamic balance error benchmark rotor that has been metrologically certified. The central control unit drives the motor to perform a stepped speed increase scan covering the entire speed range. A high-frequency photoelectric encoder is used to capture and record different set speeds in real time. The transient angular acceleration variation curves under these conditions are used to generate a theoretical benchmark acceleration time specific to this particular device through polynomial fitting and statistical denoising of a large amount of measured data. Look up the table to establish the absolute zero baseline for subsequent differential audits.

[0042] After establishing this baseline, the system performs a physical correlation calibration of the nonlinear depreciation multiplier mapping table. This process quantitatively introduces a controllable mechanical damping load by coupling a high-precision magnetic powder brake onto the centrifuge drive shaft system. During the calibration, the system gradually increases the braking torque to simulate various fault conditions ranging from slight wear to severe jamming, while simultaneously monitoring and recording the resulting acceleration hysteresis index. In addition to the corresponding motor stator winding temperature rise rate and bearing vibration energy spectral density, the processor, based on a pre-set material fatigue cumulative damage model, maps the above physical loss characteristics to dimensionless asset consumption weights, and uses a nonlinear regression algorithm to construct an accurate description. Exchange rate with asset consumption The mathematical model of the functional relationship between them is ultimately solidified in the settlement rule database, thereby ensuring that every asset value deduction is based on loss quantification logic that has been rigorously verified by physical evidence rather than subjective experience-based presuppositions.

[0043] Example 6: To address the challenge of adapting initial parameters to different individual centrifuges due to variations in manufacturing tolerances and wear conditions, this example describes a standardized pre-calibration procedure for the system deployment phase. The core of this procedure is to automatically acquire and populate key physical model parameters through a series of controlled benchmark tests, thereby eliminating the uncertainty brought about by empirical values.

[0044] When a centrifuge to be connected to the system for the first time is connected, a no-load baseline scan procedure is executed. After confirming that there is no load in the rotor chamber and that a standard test rotor is installed, the central control unit drives the motor to stabilize at four key points of 20%, 50%, 80%, and 100% of the rated speed according to a preset step sequence. At each steady-state point, the system uses a high-precision timer to record the actual time taken to accelerate from a standstill to that speed, and repeats the test three times and takes the average value to construct the reference acceleration curve of the equipment. The damping sensitivity calibration process is executed by symmetrically loading a standard counterweight of known mass (e.g., 50% of the rated load) onto the rotor and repeating the stepped speed-up test to obtain speed-up response data under load conditions. The system uses a differential algorithm to calculate the time increment of the load introduction and then solves for the load sensitivity coefficient of the equipment. Finally, based on the above measured data, the system automatically generates initial parameters for the nonlinear depreciation multiplier mapping table applicable to the equipment, and writes these parameters into the settlement rule database to complete the digital registration of the equipment.

[0045] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A fault early warning management system for a floor-standing centrifuge, characterized in that, The system is deployed on the laboratory asset information management server and includes a data communication interface, a settlement rule database, and a central settlement and audit processor. The data communication interface is used to periodically poll centrifuge devices within the local area network to obtain an operation log data stream containing the set speed, steady-state running time, and actual acceleration time. The settlement rules database is used to store the theoretical benchmark speed-up time of each model of centrifuge and the preset nonlinear depreciation multiplier mapping table, and defines the one-way function mapping relationship between the speed-up hysteresis index as a physical state quantity and the asset consumption exchange rate as a management metric. The central settlement and audit processor is used to execute the dynamic settlement process of asset value, including: retrieving the corresponding theoretical benchmark acceleration time based on the set rotation speed, calculating the time domain deviation of the actual acceleration time relative to the theoretical benchmark acceleration time to generate an acceleration hysteresis index characterizing the mechanical damping state of the equipment; The nonlinear depreciation multiplier mapping table is invoked to map the acceleration hysteresis index to a dimensionless asset consumption exchange rate; the asset consumption exchange rate is used to perform a weighted conversion on the steady-state running time to calculate the standard asset consumption equivalent for a single running task; and the equipment's full lifecycle debit account in the settlement rules database is accessed to deduct the standard asset consumption equivalent from the current account balance, and an asset disposal instruction is generated when the account balance reaches a preset administrative management threshold.

2. The fault early warning management system for a floor-standing centrifuge according to claim 1, characterized in that, The nonlinear depreciation multiplier mapping table includes a segmented penalty rule based on the compliance tolerance range: when the lag index is within the preset compliance tolerance range, the asset consumption exchange rate is locked at the base unit value. When the acceleration hysteresis index exceeds the compliance tolerance range but does not reach the blocking threshold, the asset consumption exchange rate increases exponentially and non-linearly with the increase of the acceleration hysteresis index, so as to generate a numerical loss in the management account relative to the deterioration of physical conditions.

3. The fault early warning management system for a floor-standing centrifuge according to claim 1, characterized in that, When calculating the standard asset consumption equivalent, the central settlement audit processor also introduces a fixed cost variable based on start-stop actions, transforms mechanical fatigue in non-steady-state processes into a fixed deduction amount for a single audit, and adds this fixed deduction amount to the runtime after the asset consumption exchange rate weighting to form the standard asset consumption equivalent.

4. The fault early warning management system for a floor-standing centrifuge according to claim 3, characterized in that, The Central Clearing and Settlement Audit Processor calculates the standard asset consumption equivalent using the following formula: ,in, Standard asset consumption equivalent. For steady-state operation time, The asset consumption exchange rate determined by the lag index. This is a fixed audit cost constant preset based on a single start / stop action.

5. The fault early warning management system for a floor-standing centrifuge according to claim 1, characterized in that, The central settlement audit processor is also used to perform a physical-logical self-consistency verification process for input data, including: constructing a theoretical speed-up response range model based on motor drive characteristics; comparing the actual speed-up time with the theoretical speed-up response range model; if the actual speed-up time is lower than the lower limit of the theoretical speed-up response range model, generating an audit anomaly flag indicating that the rotor load registration data is inaccurate; if the actual speed-up time is higher than the upper limit of the theoretical speed-up response range model, generating an asset aging flag indicating that the transmission system efficiency is deteriorating.

6. The fault early warning management system for a floor-standing centrifuge according to claim 1, characterized in that, The central settlement audit processor also includes a compliance credit audit module, which is used to calculate the difference between the standard asset consumption equivalent and the steady-state operating time, define the difference as the loss amount of the violation operation, and record it in the compliance credit file of the corresponding operation user; The system calculates the cumulative value of the compliance credit profile within a specific time window. When the cumulative value exceeds the preset credit threshold, an operational compliance audit report is generated for that user.

7. The fault early warning management system for a floor-standing centrifuge according to claim 1, characterized in that, The system also includes a risk trend prediction module, which is used to calculate the growth rate of the acceleration hysteresis index over multiple consecutive operating cycles, construct a time series model that reflects the evolution trend of the equipment's mechanical damping, extrapolate the expected calendar time when the equipment's full life cycle debit account balance drops to zero based on the time series model, and dynamically adjust the generation sequence of the spare parts procurement plan according to the expected calendar time.

8. The fault early warning management system for a floor-standing centrifuge according to claim 1, characterized in that, The asset disposal instruction includes writing a logical lock flag to the centrifuge control register. This logical lock flag is used to freeze the reservation and usage rights of the device at the information management level until an account reset authorization instruction is received from the administrator.

9. The fault early warning management system for a floor-standing centrifuge according to claim 1, characterized in that, The system is also equipped with a data cleaning module, which is used to identify interruption event records containing error codes in the operation log, extract the transient data at the moment the interruption event occurs and mark it as an emergency stop impact loss record, and call the preset accident penalty algorithm to calculate the additional asset consumption equivalent corresponding to the emergency stop impact loss record and directly record it into the equipment's full life cycle debit account.

10. A fault early warning management system for a floor-standing centrifuge according to claim 1, characterized in that, The data communication interface is also used to acquire the centrifuge imbalance monitoring values. The central settlement and audit processor is used to convert the imbalance monitoring values ​​into operation quality correction coefficients using a preset quality image model, and to use the operation quality correction coefficients to perform secondary weighted correction on the asset consumption exchange rate, so that the standard asset consumption equivalent includes quantitative evaluation weights for sample balance quality.

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