Vibration temperature integrated transmitter full life cycle data tracing and management method

Abstract

The present application belongs to the technical field of industrial intelligent monitoring and data processing, and particularly relates to a vibration temperature integrated transmitter full life cycle data tracing and management method, which comprises the following steps: obtaining transmitter inherent attributes and transmitter reference parameters; obtaining a total life credit, a real-time vibration value sequence and a real-time temperature value sequence of the transmitter within a preset time; calculating a working condition correction factor, a current comprehensive loss rate, an average loss rate and a trend factor, and a remaining service life; based on the size of the remaining service life, the management system automatically triggers accurate maintenance and records events; based on the event record set, an analysis report and a spare part procurement suggestion are generated. The present application converts physical loss into a visual digital account balance through a double stress model, realizes a change from time depreciation to working condition depreciation, and improves the scientificity and safety of equipment management.

Description

Technical Field

[0001] This invention relates to the field of industrial intelligent monitoring and data processing technology. More specifically, this invention relates to a method for data traceability and management throughout the entire lifecycle of an integrated vibration and temperature transmitter. Background Technology

[0002] The HTWZB integrated vibration and temperature transmitter, as a key industrial monitoring front-end device, is widely installed on the bearing housings or casings of rotating machinery such as fans, pumps, compressors, and steam turbines to capture the health status of the equipment in real time. Because its working environment is typically at the forefront of industrial sites, the transmitter faces extremely severe dual stress tests: on the one hand, continuous mechanical vibration fatigue, requiring it to withstand impact accelerations as high as 500g during equipment start-up, shutdown, or failure; on the other hand, thermal aging through high and low temperature cycles, with the operating environment temperature fluctuating drastically between -40℃ and 70℃ year-round.

[0003] However, current management models for such transmitters are generally quite rudimentary, representing a typical passive maintenance approach, and suffer from several problems. For example, there is a lack of lifespan assessment. Managers are unable to analyze the transmitter's current health balance and often simply depreciate it based on the purchase date. This leads to some equipment failing prematurely due to prolonged exposure to harsh operating conditions, creating monitoring blind spots and even triggering chain reactions, while other equipment, despite long service lives and good operating conditions, is forcibly scrapped according to a fixed lifespan, resulting in asset waste. There is also the problem of unclear fault liability. When a transmitter fails, there is a lack of traceable data evidence, often leading to conflicting accounts of whether the damage was due to a product defect or the user's on-site operating conditions, resulting in disputes. Finally, there is the problem of a passive spare parts supply chain. Because it is impossible to accurately predict the remaining lifespan of a large number of devices, companies struggle to develop scientific spare parts procurement plans, frequently resulting in inventory buildup tying up capital or stockouts impacting production.

[0004] To address the aforementioned technical challenges, this invention proposes a method for full lifecycle data traceability and management of integrated vibration and temperature transmitters. This method abandons the traditional time-based depreciation approach and innovatively treats each transmitter as an independent digital asset account. By collecting real-time data on the physical stress it experiences, and dynamically calculating and deducting its lifespan based on a physical damage model, it achieves accurate lifespan prediction, fault tracing, and supply chain optimization. Summary of the Invention

[0005] To address the technical problems of lack of equipment life assessment, unclear fault liability determination, and passive spare parts supply chain in existing technologies, this invention provides a method for full lifecycle data traceability and management of integrated vibration and temperature transmitters, including: The system analyzes the transmitter's hardware information and correlates it with the transmitter's baseline parameters from the database to obtain the transmitter's inherent attributes and baseline parameters. Based on the hardware design life and component fatigue limits of this model of equipment, the total life credit is obtained. Based on the upper limit of vibration range and the upper limit of temperature measurement, the real-time vibration value sequence and real-time temperature value sequence of the transmitter during operation within a preset time are obtained. Based on the superposition effect of transmitter vibration overload and high-temperature aging represented by the real-time vibration value and real-time temperature value, the operating condition correction factor is calculated. Combining the degree to which the current operating condition deviates from the ideal operating condition, the current comprehensive loss rate is calculated. The instantaneous comprehensive loss rate is integrated at a fixed time granularity, and the average loss rate and trend factor are calculated. The remaining service life is calculated based on the ratio of the current remaining credit to the equipment wear rate under the current actual operating conditions. Based on the remaining service life, the management system automatically triggers precise maintenance and records events. Based on the event record set, an analysis report and spare parts procurement recommendations are generated.

[0006] This invention establishes a measurable benchmark for the full lifecycle management of transmitters by creating digital identities and allocating a total lifespan credit. By acquiring vibration and temperature signals in real time and calculating loss rates using physical damage models, it transforms invisible physical stress damage into visible digital losses, realizing a shift from time-based depreciation to condition-based depreciation, greatly improving the scientific nature of equipment management. Simultaneously, through refined management methods, equipment maintenance becomes more timely and management more standardized, comprehensively improving the overall level of equipment management and providing strong support for the stable operation of industrial production.

[0007] Preferably, obtaining the transmitter's inherent properties and transmitter reference parameters includes: Based on the vibration range limit, temperature measurement limit, output signal type, installation method, and probe length parsed from the order code, the inherent attributes of the transmitter are obtained; the system automatically associates the standard design life and fatigue sensitivity index of the transmitter model from the database to obtain the transmitter's reference parameters.

[0008] Preferably, the total amount of life credit obtained includes: The system first retrieves the hardware design life of the transmitter model from the database. The hardware design life represents the theoretical maximum service time of the equipment under ideal operating conditions. At the same time, the system determines the basic consumption benchmark based on the fatigue limit of the components. This benchmark represents the life credit value that should be deducted for natural aging per unit time under standard operating conditions. Finally, the system calculates the product of the hardware design life and the basic consumption benchmark, and determines the total life credit value.

[0009] Preferably, obtaining the real-time vibration value sequence and real-time temperature value sequence of the transmitter during operation within a preset time period includes: The system reads the real-time current values ​​of the transmitter's vibration and temperature channels at a preset sampling frequency. Based on the upper limit of the vibration range and the upper limit of the temperature measurement, and according to the standard signal linear conversion formula, it calculates the real-time vibration value and the real-time temperature value. It integrates and aligns all the real-time vibration values ​​and real-time temperature values ​​within a preset time period in chronological order to obtain the real-time vibration value sequence and the real-time temperature value sequence.

[0010] Preferably, the operating condition correction factor satisfies the following expression: ; In the formula, This represents the operating condition correction factor at the current moment; This represents the real-time vibration value at the current moment in the real-time vibration value sequence. This represents the real-time temperature value at the current moment in the real-time temperature value sequence. and This represents the maximum real-time vibration value in the real-time vibration value sequence and the maximum real-time temperature value in the real-time temperature value sequence; Indicates fatigue sensitivity index; , It represents a very small positive number, and guarantees that the denominator is not 0.

[0011] The method of calculating the working condition correction factor in this invention can objectively reflect the comprehensive impact of the actual working environment on the equipment. Taking into account the differences in the pressure borne by the equipment under different operating conditions, it reflects the superimposed effect of environmental factors through reasonable calculation, avoiding the one-sidedness caused by single-factor assessment. This makes the degree of impact of the working condition on the equipment more in line with the actual situation, providing a reasonable basis for subsequent accurate calculation of equipment wear and tear and judgment of equipment health status, and making equipment condition assessment more targeted.

[0012] Preferably, the current overall loss rate satisfies the following expression: ; In the formula, This indicates the current overall loss rate; Indicates the correction factor for the current operating condition; Indicates the total amount of life credit; Indicates the standard design lifespan; It represents a very small positive number, and guarantees that the denominator is not 0.

[0013] This invention can accurately reflect the consumption rate of equipment under the current operating conditions. By combining the initial credit amount of the equipment and the actual operating condition correction factor, it avoids the rigidity of calculating losses based solely on fixed standards. This allows the equipment consumption at every moment to be objectively reflected, helping managers to grasp the current loss status of the equipment in real time. It provides an effective reference for timely adjustment of management strategies and prediction of changes in equipment status, thereby improving the precision of equipment loss management.

[0014] Preferably, the calculation of the average loss rate and trend factor includes: The system accumulates the calculated current comprehensive loss rate at a fixed frequency to obtain the current consumption limit, deducts the current consumption limit from the total life credit to obtain the current remaining credit limit; obtains all current comprehensive loss rates up to the present and calculates the average to obtain the dynamic average loss rate; calculates the first derivative of all current comprehensive loss rates up to the present through linear regression, and uses the ratio of the first derivative of the current comprehensive loss rate to the average loss rate up to the present as the loss acceleration trend factor.

[0015] This invention obtains the consumption amount by accumulating the loss rate, and calculates the mean and trend factor. It not only reflects the cumulative effect of historical losses, but also reflects the changing pattern of losses. It avoids the limitations of judgment caused by focusing only on instantaneous losses, and allows managers to understand the current remaining value of the equipment and predict future changes in losses. It provides comprehensive support for rationally arranging maintenance and assessing the remaining service life of the equipment.

[0016] Preferably, the remaining useful life satisfies the following expression: ; In the formula, Indicates the remaining useful life at the current moment; Indicates the current remaining credit limit; This represents the dynamic average loss rate up to the current moment; This represents the factor indicating the accelerating trend of losses up to the current moment; Represents the maximum value function; It represents a very small positive number, and guarantees that the denominator is not 0.

[0017] This invention takes into account the potential for accelerated equipment wear and tear, avoiding the bias caused by estimating lifespan solely based on average wear and tear. This makes the estimation results safer and more valuable, helping managers to prepare for maintenance or replacement in advance. It avoids the risks caused by premature equipment failure and reduces the waste caused by premature replacement, thus achieving reasonable planning of equipment use.

[0018] Preferably, the management system automatically triggers precise maintenance and logs events, including: The system retrieves the lifespan threshold of the equipment from the database. When the remaining lifespan of a piece of equipment is lower than the lifespan threshold, the system automatically generates a preventive maintenance work order and pushes it to the mobile terminal of the maintenance personnel. When the equipment suffers unexpected damage, the system retrieves the high-wear event records of its lifecycle account and generates an event record set.

[0019] Preferably, an analysis report and spare parts procurement recommendations are generated, including: If the event log shows multiple instances of extremely high current overall loss rate, the system will automatically generate an analysis report, determining it as a violation of operating conditions rather than a product quality issue. At the same time, the system will aggregate the remaining service life distribution data of all online transmitters in the entire plant, automatically calculate the total spare parts demand for the next 3 months, and generate accurate replenishment recommendations for the purchasing department, achieving just-in-time spare parts management and reducing inventory costs.

[0020] The beneficial effects of this invention are as follows: By establishing a digital management system for equipment, this invention transforms the physical state of equipment into measurable and traceable data information, achieving precise management of equipment throughout its entire lifecycle, from commissioning to disposal. This management method not only improves the management efficiency of individual pieces of equipment but also coordinates the health status of all equipment in the plant, providing data support for enterprises to formulate reasonable maintenance plans and procurement strategies. Simultaneously, by optimizing equipment resource allocation, unnecessary waste is reduced, management costs are lowered, and the operational efficiency of enterprises is improved. Furthermore, the application of this method can promote the transformation of equipment management from passive maintenance to proactive prediction, providing a valuable reference for the standardized and refined development of equipment management in the industrial sector. Attached Figure Description

[0021] Figure 1 This is a flowchart illustrating the method for tracing and managing the entire lifecycle data of the integrated vibration and temperature transmitter in this invention. Figure 2 This is a schematic diagram of the transmitter's dual stress cumulative loss account view, illustrating the method for tracing and managing the full lifecycle data of the integrated vibration and temperature transmitter in the invention. Figure 3 This is a schematic diagram illustrating the dynamic prediction of remaining life based on operating condition trends for the whole life cycle data traceability and management method of the integrated vibration and temperature transmitter in the invention. Figure 4 This is a schematic diagram illustrating the distribution of plant-wide asset health and intelligent decision-making for spare parts in the whole-lifecycle data traceability and management method of the integrated vibration and temperature transmitter in the invention. Detailed Implementation

[0022] This invention discloses a method for data traceability and management throughout the entire lifecycle of an integrated vibration and temperature transmitter, referring to... Figure 1 This includes steps S1-S4: S1: Parse the transmitter's hardware information and associate the transmitter's baseline parameters with the database to obtain the transmitter's inherent attributes and baseline parameters.

[0023] It should be noted that in the enterprise's equipment management system or IoT platform, a unique digital identity ID is established for each HTWZB transmitter shipped from the factory. This digital identity ID includes the transmitter's inherent attributes and reference parameters. The digital identity ID is activated by reading the RFID tag and associated with the device's inherent attributes, including the upper limit of vibration range (e.g., 50 mm / s) and the upper limit of temperature measurement (e.g., 100℃) as resolved from the order code, the output signal type, the installation method, and the probe length.

[0024] Specifically, the transmitter's hardware information is parsed and its baseline parameters are correlated with the database to obtain the transmitter's inherent attributes and baseline parameters, including: Based on the vibration range limit, temperature measurement limit, output signal type, installation method, and probe length parsed from the order code, the inherent attributes of the transmitter are obtained; the system automatically associates the standard design life and fatigue sensitivity index of the transmitter model from the database to obtain the transmitter's reference parameters.

[0025] At this point, the transmitter's inherent properties and reference parameters have been obtained.

[0026] S2: Based on the hardware design life and component fatigue limit of this model of equipment, obtain the total life credit; based on the upper limit of vibration range and the upper limit of temperature measurement, obtain the real-time vibration value sequence and real-time temperature value sequence of the transmitter during operation within a preset time; based on the superposition effect of transmitter vibration overload and high temperature aging represented by the real-time vibration value and real-time temperature value, calculate the working condition correction factor.

[0027] It should be noted that this invention establishes a digital identity and allocates a total life credit, binding the transmitter entity to a digital account, thus establishing a measurable digital benchmark for subsequent full lifecycle data tracking and value assessment. This limit is a dimensionless value representing the total physical losses the transmitter can withstand under standard design conditions, denoted as the total life credit. The system will use this total life credit as the benchmark to begin full lifecycle management of the transmitter.

[0028] Specifically, based on the hardware design life and component fatigue limits of this equipment model, a total life credit is obtained, including: The system first retrieves the hardware design life of the transmitter model from the database. The hardware design life represents the theoretical maximum service time of the equipment under ideal operating conditions. At the same time, the system determines the basic consumption benchmark based on the fatigue limit of the components. This benchmark represents the life credit value that should be deducted for natural aging per unit time under standard operating conditions. Finally, the system calculates the product of the hardware design life and the basic consumption benchmark, and determines the total life credit value.

[0029] At this point, the total life credit of the transmitter was obtained.

[0030] It should be noted that the signal output by the transmitter not only reflects the health of the device under test, but also directly reflects the degree of damage to the transmitter itself. The system collects vibration and temperature signals in real time through an analog signal acquisition card.

[0031] Preferably, based on the upper limit of the vibration range and the upper limit of the temperature measurement, a real-time vibration value sequence and a real-time temperature value sequence are obtained during the operation of the transmitter within a preset time period, including: The system reads the real-time current values ​​of the transmitter's vibration and temperature channels at a preset sampling frequency. Based on the upper limit of the vibration range and the upper limit of the temperature measurement, and according to the standard signal linear conversion formula, it calculates the real-time vibration value and the real-time temperature value. It integrates and aligns all the real-time vibration values ​​and real-time temperature values ​​within a preset time period in chronological order to obtain the real-time vibration value sequence and the real-time temperature value sequence.

[0032] Thus, the real-time vibration value sequence and real-time temperature value sequence of the transmitter were obtained.

[0033] It should be noted that during the operating cycle of rotating machinery, smooth operation is the norm, but occasional start-stop shocks or process fluctuations are the critical moments that cause sensor damage. Linear cumulative models cannot explain why short-term overload can lead to years of lifespan reduction. From the physical damage mechanism, it is known that there is a significant nonlinear exponential relationship between stress and damage. When operating conditions approach or exceed design limits, the damage rate increases exponentially. Therefore, this invention must introduce a dynamic operating condition correction factor to adjust the billing rate. This factor can maintain a low rate under stable operating conditions and instantly increase the rate under severe operating conditions, thus truly reflecting the irreversible damage caused to precision electronic equipment by extreme environments and avoiding the masking of fatal impact damage by averaging.

[0034] Preferably, based on the superimposed effect of transmitter vibration overload and high-temperature aging characterized by real-time vibration values ​​and real-time temperature values, a working condition correction factor is calculated, including: The operating condition correction factor satisfies the following expression: ; In the formula, This represents the operating condition correction factor at the current moment; This represents the real-time vibration value at the current moment in the real-time vibration value sequence. This represents the real-time temperature value at the current moment in the real-time temperature value sequence. and This represents the maximum real-time vibration value in the real-time vibration value sequence and the maximum real-time temperature value in the real-time temperature value sequence; Indicates fatigue sensitivity index; , It represents a very small positive number, and guarantees that the denominator is not 0.

[0035] In the formula, and The normalized load ratios of the real-time vibration and temperature values ​​at the current moment relative to the maximum value of the current sequence were calculated respectively. and It realizes the transformation of physical quantities with different dimensions into dimensionless relative intensity indices; or This indicates that a fatigue sensitivity index is introduced using a power function, reflecting the physical fact that when the vibration load approaches its peak value, its ability to damage the equipment's lifespan increases exponentially. This indicates the degree of impact of the current operating conditions on the equipment. The larger the value, the more severe the damage to the equipment's lifespan caused by the current operating conditions.

[0036] Thus, the operating condition correction factor for the current moment has been obtained.

[0037] S3: Calculate the current overall loss rate based on the degree to which the current operating conditions deviate from the ideal operating conditions; integrate the instantaneous overall loss rate with a fixed time granularity, and calculate the average loss rate and trend factor.

[0038] It should be noted that traditional periodic maintenance strategies have a significant blind spot in terms of time granularity, failing to capture the abrupt changes from normal operation to failure in the next second. The current comprehensive loss rate proposed in this invention aims to calculate the macroscopic lifespan consumption, pinpointing it to each sampling cycle. This allows managers to instantly see the specific cost of the current operating conditions on the equipment. This invention constructs a dimensionless damage model based on range normalization, directly utilizing the transmitter's inherent properties as an evaluation benchmark, avoiding errors from manually setting empirical constants. By combining the operating condition correction factor with the basic aging rate, the system can calculate the precise rate of lifespan loss at every moment. This high-frequency, refined calculation makes it possible to capture the hidden damage caused by transient shocks.

[0039] Specifically, based on the degree to which the current operating conditions deviate from the ideal operating conditions, the current overall loss rate is calculated, including: The current overall loss rate satisfies the following expression: ; In the formula, This indicates the current overall loss rate; Indicates the correction factor for the current operating condition; Indicates the total amount of life credit; Indicates the standard design lifespan; It represents a very small positive number, and guarantees that the denominator is not 0.

[0040] In the formula, express The larger the value, the faster the device's lifespan is being consumed at that moment; Indicates to Divide by What we get is the lifespan resources consumed per unit of time under ideal conditions; It indicates the degree to which the current operating condition deviates from the ideal operating condition.

[0041] For example, if the baseline consumption under standard operating conditions is 2 points / hour, then take... Collected , , , , Current operating conditions , , Points / hour, which means that under this operating condition, the transmitter consumes approximately 4.048 life credits in 1 hour of operation, which is more than twice that of the standard operating condition.

[0042] It should be noted that the overall loss rate at a single moment only reflects the current pressure, while the final failure of the equipment is the result of historical cumulative effects; that is, every small overload depletes the equipment's fatigue reserves. This invention transforms the discrete rate into a continuous total by integrating the instantaneous overall loss rate over time, thereby updating the remaining credit limit in real time. This process is not merely a numerical subtraction, but a real-time mapping of the physical entity's health status. To provide maintenance and procurement personnel with forward-looking decision-making support, the system predicts the transmitter's current remaining credit limit based on historical loss trends. To prevent drastic jumps in predicted values ​​or logical errors due to fluctuations in operating conditions, this invention introduces a dynamic average loss rate and a loss acceleration trend factor; ensuring that the prediction results reflect both long-term wear accumulation and recent operating condition trends, achieving an organic combination of static inventory and dynamic variables.

[0043] Preferably, the instantaneous overall loss rate is integrated at a fixed time granularity, and the average loss rate and trend factor are calculated, including: The system accumulates the calculated current comprehensive loss rate at a fixed frequency to obtain the current consumption limit, deducts the current consumption limit from the total life credit to obtain the current remaining credit limit; obtains all current comprehensive loss rates up to the present and calculates the average to obtain the dynamic average loss rate; calculates the first derivative of all current comprehensive loss rates up to the present through linear regression, and uses the ratio of the first derivative of the current comprehensive loss rate to the average loss rate up to the present as the loss acceleration trend factor.

[0044] S4: Calculate the remaining service life based on the ratio of the current remaining credit limit to the equipment wear rate under the current actual operating conditions; based on the remaining service life, the management system automatically triggers precise maintenance and records the events; based on the event record set, an analysis report and spare parts procurement recommendations are generated.

[0045] It's important to note that simply relying on the current remaining credit limit divided by the dynamic average wear rate to predict equipment lifespan often yields overly optimistic results. However, in real-world industrial scenarios, equipment failures are often accompanied by a gradual deterioration of operating conditions. For example, bearing wear leads to increased vibration, and this deterioration has an acceleration effect—the dynamic average wear rate itself is increasing faster. If this trend is not considered, the predicted equipment lifespan will be far longer than the actual lifespan. Therefore, this invention introduces a wear acceleration trend factor when calculating remaining usable time. This is a defensive algorithmic logic; when a deteriorating trend in operating conditions is detected, the algorithm proactively penalizes the prediction result, shortening the estimated number of days, thereby forcing management to intervene early. This proactive calculation strategy effectively addresses common gradual failures in industrial settings, preventing the illusion of stability from being misled.

[0046] Specifically, the remaining useful life is calculated based on the ratio of the current remaining credit limit to the equipment wear rate under current actual operating conditions, including: The remaining useful life satisfies the following expression: ; In the formula, Indicates the remaining useful life at the current moment; Indicates the current remaining credit limit; This represents the dynamic average loss rate up to the current moment; This represents the factor indicating the accelerating trend of losses up to the current moment; Represents the maximum value function; It represents a very small positive number, and guarantees that the denominator is not 0.

[0047] In the formula, Indicates adoption The limitation is set, meaning it is only applicable when the operating conditions show a worsening trend. Only when the system considers accelerated depreciation in its forecasts will the operating conditions improve or stabilize. If the forecast is based on the current average level, then it reflects the defensive pessimism principle in safety management, preventing blind optimism in extending the forecast life due to short-term improvement in operating conditions, which could lead to insufficient spare parts preparation. This represents the remaining lifespan of the equipment, divided by the current actual rate of wear and tear, to obtain the time the equipment can still operate safely.

[0048] At this point, the remaining lifespan of the equipment at the current moment has been obtained.

[0049] It's important to note that in modern large-scale factories, there are hundreds or even thousands of transmitters. Relying on manual data checks to determine maintenance needs is not only inefficient but also prone to oversights leading to missed inspections. Furthermore, different health states of transmitters require different resources: naturally aging equipment requires routine logistics and procurement, while equipment experiencing sudden high wear and tear requires in-depth technical analysis. Without a tiered decision-making mechanism, the large volume of information pushed by the system will become mere alarm noise, drowning out critical issues. This invention, by setting intelligent thresholds, transforms calculation results into specific action instructions. This automated triage mechanism achieves a closed loop from data monitoring to business execution, ensuring that each type of problem directly reaches the corresponding responsible party, significantly reducing communication costs and decision-making delays.

[0050] Preferably, based on the remaining service life, the management system automatically triggers precise maintenance and records the events, including: The system retrieves the lifespan threshold of the equipment from the database. When the remaining lifespan of a piece of equipment is lower than the lifespan threshold, the system automatically generates a preventive maintenance work order and pushes it to the mobile terminal of the maintenance personnel. When the equipment suffers unexpected damage, the system retrieves the high-wear event records of its lifecycle account and generates an event record set.

[0051] It's important to note that the ultimate goal of equipment management is not only to ensure smooth operation but also to optimize costs and clarify responsibilities. On the supply chain side, traditional inventory management often leads to either inventory buildup or downtime due to inaccurate demand forecasting. Just-in-Time (JIT) procurement, achieved through RUL (Rich, Lowest Rank) forecasting, can fundamentally resolve this contradiction. However, in the after-sales service sector, blame-shifting often occurs due to product quality issues or improper use. This invention can objectively reproduce the operating history before a failure, which not only protects the manufacturer's rights but also encourages process improvements to reduce equipment damage. Therefore, this invention transforms dry data into commercially valuable reports and recommendations, breaking down the barriers between technical data and business operations.

[0052] Preferably, based on the event log set, an analysis report and spare parts procurement recommendations are generated, including: If the event log shows multiple instances of extremely high current overall loss rate, the system will automatically generate an analysis report, determining it as a violation of operating conditions rather than a product quality issue. At the same time, the system will aggregate the remaining service life distribution data of all online transmitters in the entire plant, automatically calculate the total spare parts demand for the next 3 months, and generate accurate replenishment recommendations for the purchasing department, achieving just-in-time spare parts management and reducing inventory costs.

[0053] It should be noted that, Figure 2This graph presents a view of the transmitter's dual stress cumulative loss account, showcasing the interface for micro-management of a single transmitter. During the 11-12 hour interval, the real-time vibration stress curve (i.e., the real-time vibration value curve) suddenly rises, indicating a strong impact at that moment. Correspondingly, the instantaneous life loss rate curve below, i.e., the current comprehensive loss rate curve, rises sharply like a mountain peak, indicating that the equipment suffered severe damage at that instant. The equipment life credit balance curve above, i.e., the current remaining credit limit curve, experiences a precipitous vertical drop at this moment, visually illustrating the dynamic logic of a sudden, strong impact causing a surge in life loss.

[0054] Figure 3 This is a dynamic prediction chart of remaining lifetime based on operating condition trends. The chart includes a dynamic prediction curve representing the accelerated wear trend factor introduced in this invention. In the abnormal range where operating conditions show a deteriorating trend, the remaining lifetime shown by the dynamic prediction curve of this invention shortens rapidly, with the predicted value dropping from 330 days to 274 days; while the static prediction curve of the background technology remains around 330 days. This difference clearly demonstrates the technical advantage of this invention in providing early warning of gradual failures through a defensive pessimistic principle. In the stable operating range, the prediction curve of this invention tends to be consistent with the curve of the background technology.

[0055] Figure 4 The chart serves as a distribution map of the plant's asset health and intelligent decision-making for spare parts. The main body is a circular statistical chart that clearly shows the distribution of the health status of all transmitters in the plant. The center of the chart prominently displays the recommended spare parts procurement quantity for the next month, which is automatically calculated by the system based on high-risk equipment and the number of equipment that is predicted to fail. This intuitively demonstrates the supporting role of data in supply chain decision-making.

[0056] This completes the full lifecycle data traceability and management of the integrated vibration and temperature transmitter.

[0057] While various embodiments of the invention have been shown and described in this specification, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Many modifications, alterations, and alternatives will occur to those skilled in the art without departing from the spirit and essence of the invention.

Claims

1. A method for full lifecycle data traceability and management of integrated vibration and temperature transmitters, characterized in that: include: Parse the transmitter's hardware information and associate the transmitter's baseline parameters with the database to obtain the transmitter's inherent properties and baseline parameters; Based on the transmitter's hardware design life and component fatigue limits, the total life credit is obtained, including: the system first retrieves the transmitter's hardware design life from the database, which represents the theoretical maximum service time of the equipment under ideal operating conditions; simultaneously, the system determines a basic consumption benchmark based on component fatigue limits, which represents the life credit value that should be deducted for natural aging per unit time under standard operating conditions; finally, the system calculates the product of the hardware design life and the basic consumption benchmark, and determines this product as the total life credit; based on the upper limit of vibration range and the upper limit of temperature measurement, the system obtains the real-time vibration value sequence and real-time temperature value sequence of the transmitter during operation within a preset time; based on the superposition effect of transmitter vibration overload and high-temperature aging represented by the real-time vibration value and real-time temperature value, the system calculates the operating condition correction factor; Calculate the current overall loss rate based on the degree to which the current operating conditions deviate from the ideal operating conditions; integrate the instantaneous overall loss rate with a fixed time granularity, and calculate the average loss rate and trend factor; The system accumulates the calculated current comprehensive loss rate at a fixed frequency to obtain the current consumption limit, deducts the current consumption limit from the total life credit limit to obtain the current remaining credit limit; and calculates the remaining service life based on the ratio of the current remaining credit limit to the equipment loss rate under the current actual operating conditions. The remaining service life satisfies the following expression: In the formula, Indicates the remaining useful life at the current moment; Indicates the current remaining credit limit; This represents the dynamic average loss rate up to the current moment; This represents the factor indicating the accelerating trend of loss up to the current moment; it is dimensionless. Represents the maximum value function; It represents extremely small positive numbers, ensuring that the denominator is not 0; based on the remaining service life, the management system automatically triggers precise maintenance and records events; based on the event record set, it generates analysis reports and spare parts procurement recommendations.

2. The method for full lifecycle data traceability and management of the integrated vibration and temperature transmitter according to claim 1, characterized in that, The process of obtaining the transmitter's inherent properties and reference parameters includes: Based on the vibration range limit, temperature measurement limit, output signal type, installation method, and probe length obtained from the order code, the inherent properties of the transmitter are obtained; the system automatically associates the standard design life and fatigue sensitivity index of the transmitter from the database to obtain the transmitter's reference parameters.

3. The method for full lifecycle data traceability and management of the integrated vibration and temperature transmitter according to claim 1, characterized in that, The process of obtaining the real-time vibration value sequence and real-time temperature value sequence of the transmitter during operation within a preset time includes: The system reads the real-time current values ​​of the transmitter's vibration and temperature channels at a preset sampling frequency. Based on the upper limit of the vibration range and the upper limit of the temperature measurement, and according to the standard signal linear conversion formula, it calculates the real-time vibration value and the real-time temperature value. It integrates and aligns all the real-time vibration values ​​and real-time temperature values ​​within a preset time period in chronological order to obtain the real-time vibration value sequence and the real-time temperature value sequence.

4. The method for full lifecycle data traceability and management of the integrated vibration and temperature transmitter according to claim 1, characterized in that, The operating condition correction factor satisfies the following expression: ； In the formula, This represents the operating condition correction factor at the current moment; This represents the real-time vibration value at the current moment in the real-time vibration value sequence. This represents the real-time temperature value at the current moment in the real-time temperature value sequence. and This represents the maximum real-time vibration value in the real-time vibration value sequence and the maximum real-time temperature value in the real-time temperature value sequence; Indicates fatigue sensitivity index; , It represents a very small positive number, and guarantees that the denominator is not 0.

5. The method for full lifecycle data traceability and management of the integrated vibration and temperature transmitter according to claim 1, characterized in that, The current overall loss rate satisfies the following expression: ； In the formula, This indicates the current overall loss rate; Indicates the correction factor for the current operating condition; Indicates the total amount of life credit; Indicates the standard design lifespan; It represents a very small positive number, and guarantees that the denominator is not 0.

6. The method for full lifecycle data traceability and management of the integrated vibration and temperature transmitter according to claim 1, characterized in that, The calculation of the average loss rate and trend factor includes: Obtain all current comprehensive loss rates up to date and calculate the mean to obtain the dynamic average loss rate; calculate the first derivative of all current comprehensive loss rates up to date through linear regression, and use the ratio of the first derivative of the current comprehensive loss rate to the current average loss rate as the loss acceleration trend factor.

7. The method for full lifecycle data traceability and management of the integrated vibration and temperature transmitter according to claim 1, characterized in that, The management system automatically triggers precise maintenance and logs events, including: The system retrieves the lifespan threshold of the equipment from the database. When the remaining lifespan of a piece of equipment is lower than the lifespan threshold, the system automatically generates a preventive maintenance work order and pushes it to the mobile terminal of the maintenance personnel. When the equipment suffers unexpected damage, the system retrieves the high-wear event records of its lifecycle account and generates an event record set.

8. The method for full lifecycle data traceability and management of the integrated vibration and temperature transmitter according to claim 1, characterized in that, The generated analysis report and spare parts procurement recommendations include: If the event log shows multiple instances of extremely high current overall loss rate, the system will automatically generate an analysis report, determining it as a violation of operating conditions rather than a product quality issue. At the same time, the system will aggregate the remaining service life distribution data of all online transmitters in the entire plant, automatically calculate the total spare parts demand for the next 3 months, and generate accurate replenishment recommendations for the purchasing department, achieving just-in-time spare parts management and reducing inventory costs.

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