Configuration system for rotating machinery monitoring and operation method

Abstract

The invention discloses a configuration system for monitoring a rotating machine and an operation method. The configuration system comprises a system configuration module, an equipment management module, a picture configuration module, a communication service module, a data management module, an alarm system module, a project management module and a user management module. The system configuration module is used for configuring a system architecture; the equipment management module is used for managing equipment configured by a project, can configure various rotary mechanical control models, and comprises a pump set electromagnetic valve model, a booster pump model, an electric adjusting valve model, a pressure electromagnetic valve model, a power supply model, a modal test model and a group module model; the picture configuration module is used for automatically generating a basic picture and a matched alarm picture, a tendency chart picture and a report picture based on variable attributes and engineering configuration data of associated equipment; and providing a preset control function and a user-defined control function so as to realize free combination of control elements by a user. During operation, the client communicates with the server to realize data monitoring, alarming and reporting functions.

Description

Technical Field

[0001] This invention belongs to the field of configuration monitoring technology, specifically relating to a configuration system and operation method for monitoring rotating machinery. Background Technology

[0002] As a key supporting system for rotating machinery, the monitoring system is responsible for monitoring the equipment's operating status, controlling the process flow, and handling emergencies throughout the entire testing or production process. It places extremely high demands on detection accuracy and the safety and stability of process control. Control layer products such as PLCs and DCSs serve as the control core of the rotating machinery monitoring system, used for data transmission of key operating parameters, process control of solenoid valves, electrically adjustable valves, vacuum pumps, and circulating water machines, as well as real-time acquisition of process parameters such as pressure, temperature, flow rate, and power supply. Their performance directly determines the safety, stability, and reliability of the rotating machinery's operation.

[0003] In the field of industrial automation, configuration software is widely used in the development of monitoring systems. General-purpose configuration software such as Siemens WinCC offers rich functionality for screen configuration, data acquisition, and alarm management. However, these general-purpose software programs have the following limitations:

[0004] (1) Lack of specialization: General configuration software is not designed for the field of rotating machinery and lacks special control models and controls for this field (such as pump solenoid valves, booster pump modules, etc.), which requires developers to do a lot of customization work, resulting in long development cycles and low efficiency.

[0005] (2) Reliability issues: The rotating machinery monitoring system has high reliability requirements and needs to support server redundancy, equipment redundancy and data redundancy backup, but general software is not optimized enough in terms of redundancy switching and real-time synchronization.

[0006] (3) High integration complexity: Rotating machinery systems often involve proprietary control layer equipment and various third-party equipment (such as PLC and communication bus). General software is cumbersome to configure in terms of protocol parsing and variable mapping, and is prone to errors.

[0007] (4) Weak cross-platform support: Many general-purpose software programs mainly support Windows systems and are difficult to adapt to domestic operating systems and CPUs, which limits their application in an autonomous environment.

[0008] Therefore, there is an urgent need in this field for a dedicated configuration software that can simplify the development process of rotating machinery monitoring systems and improve standardization and reliability. Summary of the Invention

[0009] The purpose of this invention is to overcome the shortcomings of existing technologies and design a configuration system and operation method for monitoring rotating machinery. Specifically designed for the field of rotating machinery, this invention supports system architecture configuration, equipment management, automatic screen generation, and data management, significantly shortening the development cycle and improving the consistency and reliability of the monitoring system.

[0010] This invention is achieved through the following technical solution:

[0011] A configuration system for monitoring rotating machinery includes: a system configuration module, an equipment management module, a screen configuration module, a communication service module, a data management module, an alarm system module, an engineering management module, and a user management module;

[0012] The system configuration module is used to configure the system architecture;

[0013] The equipment management module is used to manage the equipment configured in the project. It can configure various rotating machinery control models, including: pump group solenoid valve model, booster pump model, electric regulating valve model, pressure solenoid valve model, power supply model, modal test model, and group module model, and configure relevant parameters.

[0014] The screen configuration module is used to automatically generate basic screens and corresponding alarm screens, trend chart screens, and report screens based on variable attributes and engineering configuration data of associated devices; it provides preset control and custom control functions to allow users to freely combine control elements.

[0015] The communication service module is used to implement industrial communication functions;

[0016] The data management module is used to manage engineering configuration data and real-time data;

[0017] The alarm system module includes three alarm levels: recording, prompting, and alarming, with the severity increasing sequentially. It is mainly divided into two categories: process value alarms and system alarms, and provides audible and visual alarms.

[0018] The project management module is used to create, query, open, modify, save, and import / export projects during the development process, facilitating the rapid deployment of projects on the rotating machinery site.

[0019] The user management module is used for role-based access control, providing account and password login, permission allocation, and operation log recording.

[0020] In the above technical solution, the variable attributes include name, type, address, and alarm threshold.

[0021] The basic workflow of the configuration monitoring system in the above technical solution includes the following steps:

[0022] S1: First, define the system architecture and device parameters through the system configuration module and device management module;

[0023] S2: Then use the screen configuration module to automatically generate or customize the screen;

[0024] S3: During runtime, the client communicates with the server to implement data monitoring, alarm, and reporting functions.

[0025] In the above technical solution, the configuration monitoring system adopts a C / S architecture. Its basic engineering deployment architecture includes several servers, several clients, and several field stations. The servers are used to aggregate data, the clients are used to aggregate data from several field stations, and the field stations are used to interact with the equipment.

[0026] In the above technical solution, the configuration monitoring system includes a presentation layer, an access layer, a business relationship layer, business support, a data support layer, a storage layer, basic support, and service management. The presentation layer provides screen support for the configuration software and its operation. The access layer uses a Socket interface to manage message queues. The business relationship layer is used for software authorization, authentication, load and hot standby monitoring. The business support is the functional implementation part of the software, including both configuration and operation aspects. In terms of configuration, it supports data acquisition configuration, variable processing, third-party communication, alarm settings, data processing, and log management. In terms of operation, the server provides screen configuration, supporting screens, dynamic flowcharts, data query, and reporting functions, while the client provides screen operation, authorization settings, alarms, and local persistence management functions. The data support layer includes thread pool management, SQL executor, database and table access, file access, device access, acquired data processing, data quality monitoring, MQ access, cache access, and Socket data transmission. The storage layer includes a business database, cache and hot data, client persistence, and module communication. Service management includes running thread monitoring, alarm generation and recovery, client / server data support, and process monitoring.

[0027] In the above technical solution, the engineering configuration data includes various configuration parameters, internal logical variables, and functional variables of the entire project; the real-time data includes real-time acquisition and output point data, operation log data, and error logs.

[0028] In the above technical solution, the server stores the project configuration data and real-time data of all sites; the client obtains the project configuration data and real-time data outside the local site from the server database through database synchronization, and stores the real-time data of the local site in real time; the field station reads and writes the project configuration data from the server and stores the real-time data of the local site.

[0029] In the above technical solution, when configuring the pump group solenoid valve control model, the model serial number is automatically generated to ensure the uniqueness of the model in the data. Then, the user can link variables for the pump inlet pressure, pump group control, pump inlet solenoid valve, backing pump, Roots pump, and remote and local settings as needed. The pump group solenoid valve control model includes: pump group start-stop control, backing pump interlock start-stop control, and pump group interlock start-stop control. After configuring the pump group solenoid valve in the equipment configuration interface, a pump group solenoid valve control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

[0030] In the above technical solution, when configuring the booster pump control model, the model serial number is automatically generated to ensure the uniqueness of the model in the data. Then, the user can link variables for the pump inlet pressure, pump inlet solenoid valve, booster pump, and remote and local settings as needed. In the booster pump control model, interlocking control of the booster pump, solenoid valve, and pump inlet pressure is realized. After configuring the booster pump solenoid valve in the equipment configuration interface, a booster pump solenoid valve control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

[0031] In the above technical solution, when configuring the electrically adjustable valve control model, a model serial number will be automatically generated to ensure the uniqueness of the model in the data. Then, the user can link variables as needed for current opening degree, setting opening degree, check control, setting step size, self-test control, manual up adjustment, manual down adjustment, manual full open, manual full close, full open state, full close state, upstream pressure, downstream pressure, target pressure, P, I, D, self-tuning start control, stop control, start state, stop device, self-tuning control, PID control, and remote / local control. In the electrically adjustable valve control model, the control methods include manual control, PID control, and PID parameter self-tuning. After configuring the electrically adjustable valve in the equipment configuration interface, an electrically adjustable valve control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

[0032] In the above technical solution, when configuring the pressure solenoid valve model, a model serial number will be automatically generated to ensure the uniqueness of the model in the data. Then, the user can configure the pressure measuring points and solenoid valves as needed. The pressure solenoid valve control model includes the interlocking control of the pressure measuring points and solenoid valves. After configuring the pressure solenoid valve in the equipment configuration interface, a pressure solenoid valve control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

[0033] In the above technical solution, when configuring the power control model, the model serial number is automatically generated to ensure the uniqueness of the model in the data; then, the user links variables for active power, reactive power, apparent power, operating status, and fault status as needed; after configuring the power model in the device configuration interface, a power control will be generated during screen configuration, and various parameters can be modified through the control configuration configuration page during screen configuration.

[0034] In the above technical solution, when configuring the modal test control model, a model serial number will be automatically generated to ensure the uniqueness of the model in the data. Then, the user can link variables for modal acquisition mode, excitation point, response point, start control and status, and stop control and status as needed. After configuring the modal test model in the device configuration interface, a modal test control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

[0035] In the above technical solution, when configuring the group module model, the model number is automatically generated to ensure the uniqueness of the model in the data; then the user configures the number of units and link variables of the group module as needed, and the maximum, minimum, average and slip values ​​are automatically calculated, and the upper and lower limits are modified and configured.

[0036] In the above technical solution, the automatic image generation process is as follows:

[0037] S1: Obtain system screen resolution parameters and the specific number of variables and models within the project;

[0038] S2: Calculate the number of models and the canvas area occupied by a single model;

[0039] S3: Calculate the number of digital and analog quantities other than variables used by the model, and calculate the canvas area occupied by the digital and analog quantity controls.

[0040] S4: Based on the total area occupied by the above screens and the number of various controls, arrange them in the canvas according to the edge distance parameter and control spacing parameter, and calculate the number of basic screens and the number of controls in each screen;

[0041] S5: Add special screens such as alarms, queries, and preset reports after several basic screens;

[0042] S6: Perform manual adjustments to complete the image generation.

[0043] The advantages and beneficial effects of this invention are as follows:

[0044] (1) High specialization: It is customized for the field of rotating machinery, integrating special control models and controls to reduce redundant development and improve the degree of standardization.

[0045] (2) High development efficiency: Through automatic screen generation, navigation configuration and custom controls, the project development is simplified and the cycle is shortened.

[0046] (3) High reliability: Supports server redundancy, equipment redundancy and data redundancy backup, enhancing system fault tolerance; cross-platform design adapts to domestic environment, and runs smoothly.

[0047] (4) Easy integration: compatible with multiple devices and protocols, unified variable management, reducing integration complexity.

[0048] (5) Excellent user experience: Provides intuitive screen editing tools, multi-permission management and real-time data display to improve operational efficiency. Attached Figure Description

[0049] Figure 1 This is a schematic diagram of the basic workflow of the configuration system for monitoring rotating machinery according to the present invention;

[0050] Figure 2 This is an engineering layout architecture diagram of the configuration system for monitoring rotating machinery according to the present invention;

[0051] Figure 3 A schematic diagram of the software architecture and functional division;

[0052] Figure 4 This diagram illustrates the data redundancy method and the system data link.

[0053] Figure 5 This is a schematic diagram of the system's real-time data link;

[0054] Figure 6 This is a schematic diagram of the configuration and operation interface of the pump set solenoid valve control model.

[0055] Figure 7 This is a schematic diagram of the booster pump model configuration and operating interface;

[0056] Figure 8 This is a schematic diagram of the configuration and operation interface of an electrically controlled valve model.

[0057] Figure 9 This is a schematic diagram of the configuration and operation interface of a pressure solenoid valve model.

[0058] Figure 10 This is a schematic diagram of the power supply model configuration and operating interface.

[0059] Figure 11 This is a schematic diagram of the configuration and operation interface of the modal testing model;

[0060] Figure 12 This is a schematic diagram of the configuration and operation interface of the grouped module model;

[0061] Figure 13 Automatically generate flowcharts for the screen;

[0062] Figure 14 This is a schematic diagram of the monitoring system screen;

[0063] Figure 15 This is a schematic diagram of the process piping flow diagram editing interface;

[0064] Figure 16 This is a flowchart of the process for switching over redundant servers.

[0065] In the diagram: 1 is the server, 2 is the client, 3 is the field station and display, 4 is the equipment in use, 5 is the backup equipment, 6 is the industrial Ethernet, 7 is the presentation layer, 8 is the access layer, 9 is the business network relationship layer, 10 is the business support, 11 is the data support layer, 12 is the storage layer, 13 is the basic support, and 14 is the service management.

[0066] For those skilled in the art, other related figures can be obtained from the above figures without any creative effort. Detailed Implementation

[0067] To enable those skilled in the art to better understand the present invention, the technical solution of the present invention will be further described below with reference to specific embodiments.

[0068] This embodiment designs a configuration system for monitoring rotating machinery, including: a system configuration module, an equipment management module, a screen configuration module, a communication service module, a data management module, an alarm system module, an engineering management module, and a user management module.

[0069] The system configuration module is used to configure the system architecture, supporting up to two servers (dual-machine hot standby) and multiple clients. It provides navigation-style guidance to configure server, client, and device parameters and generate database forms. It supports the addition and communication testing of various communication devices (such as RS232 / 485, CAN, TCP / IP, etc.) and OPC variables.

[0070] The equipment management module is used to manage the equipment configured in the project. It can configure various rotating machinery control models (e.g., pump solenoid valve model, booster pump model, electronic control valve model, pressure solenoid valve model, power supply model, modal test model, and group module model) and configure relevant parameters. These devices can be composed of controller modules with attached DI / DO / AI / AO / functional modules, or they can be devices that support protocols such as MODBUS RTU / TCP, PROFINET, and OPC UA / DA. Variables can be mapped to the variable table of the configuration monitoring system.

[0071] The screen configuration module supports automatic screen generation and secondary development. Based on project configuration data (such as variable attributes and device associations), it automatically generates basic screens (resolution at least 1080P, supporting multi-screen display) and accompanying alarm screens, trend chart screens, report screens, etc. It provides preset controls (such as analog quantity modules, Boolean quantity modules, and special modules) and custom control functions, allowing users to freely combine control elements. Screen editing is supported (pixel-level movement, variable drag-and-drop association, layout tools).

[0072] The communication service module is used to implement industrial communication functions and supports multiple bus protocols and OPC server / client.

[0073] The data management module is used to manage project configuration data and real-time data. Variable attributes include name, type, address, alarm threshold, etc., and support adding, deleting, modifying, and querying variables. The database is compatible with Linux and Kylin systems, supports data redundancy backup, and has local storage and synchronization mechanisms to optimize query speed.

[0074] The alarm system module includes three alarm levels: recording, prompting, and alarming, with the severity increasing in that order. It is mainly divided into two categories: process value alarms and system alarms, and also provides audible and visual alarms.

[0075] The project management module is used to create, query, open, modify, save, and import / export projects during the development process, facilitating the rapid deployment of projects on the rotating machinery site.

[0076] The user management module is used for role-based access control (such as administrator, engineer, and experimenter), providing account password login, permission allocation, and operation log recording.

[0077] See appendix Figure 1 The basic workflow of the configuration system for monitoring rotating machinery of the present invention includes the following steps:

[0078] S1: First, define the system architecture and device parameters through the system configuration module and device management module.

[0079] S2: Then use the screen configuration module to automatically generate or customize the screen.

[0080] S3: During runtime, the client communicates with the server to implement functions such as data monitoring, alarms, and reports. It supports redundancy switching and time synchronization (NTP mechanism).

[0081] The configuration system for monitoring rotating machinery of the present invention adopts a client / server architecture, see appendix. Figure 2The basic engineering deployment architecture includes several servers (1), several clients (2), and several field stations (3). Servers (1) are used to aggregate data, clients (2) are used to aggregate data from several field stations (3), and field stations (3) are used to interact with devices (4). Since this configuration monitoring system needs to adapt to systems of different sizes, some systems may not have a complete set of servers (1), clients (2), and field stations (3). For example, if system A only has space for two PCs, one PC will act as server (1) to aggregate data, and the other will act as client (2) or field station (3) to communicate with device (4) in real time. In this case, the other client needs to back up the server's data and monitor the server's status in real time. If the server fails, the system needs to switch to that PC to provide all functions. Redundancy mechanisms between servers and between servers and other PCs will be explained later. Alternatively, to put it simply, the system only has server and non-server PCs. The difference between clients and field stations is not significant; both need to have redundancy switching, data synchronization, various communication functions, and video services. The specific functions to be implemented need to be selected in the configuration monitoring system. Both the active device 4 and the standby device 5 are connected to the industrial Ethernet 6, and redundancy switching is performed through the controller redundancy mechanism.

[0082] Figure 3This is a functional structure diagram of the configuration monitoring system. The system mainly includes a presentation layer (7), an access layer (8), a business relationship layer (9), business support (10), a data support layer (11), a storage layer (12), basic support (13), and service management (14). The presentation layer (7) primarily provides screen support for the configuration software and its operation, and is mainly developed using QT, Three.js, and Vue. The access layer (8) uses a Socket interface and MQ (Kafka) message queue technology. Its core function is that producers send messages to a temporary "queue," and consumers retrieve messages from this queue sequentially for processing. The business relationship layer (9) mainly includes software authorization, authentication, load balancing, and hot standby monitoring. Business Support Layer 10 is the functional implementation part of the software, mainly including configuration and operation. In terms of configuration, it supports data acquisition configuration, variable processing, and third-party communication (serial port, CAN, TCP / IP, etc.), and allows for alarm settings, data processing, and log management. In terms of operation, the server provides screen configuration, supporting screens, dynamic flowcharts, data query, and reporting functions, while the client provides screen operation, authorization settings, alarms, and local persistence management functions. Data Support Layer 11 mainly includes thread pool management, SQL executor, database and table access, file access, device access, acquired data processing, data quality monitoring, MQ access, cache access, and Socket data transmission functions. Storage Layer 12 includes the business database (MySQL), cache and hot data (Redis), client persistence (SQLite), and module communication (Kafka). Service Management Layer 14 mainly includes running thread monitoring, alarm generation and recovery, client / server data support, and process monitoring.

[0083] Figure 4This diagram illustrates data redundancy methods and system data links. When the project is large-scale and includes two servers, redundancy method 1 (inter-server redundancy) should be selected. In this case, all data on server 1 will be synchronized with server 2 periodically using a database synchronization mechanism or some other synchronization mechanism. Simultaneously, server 2 monitors server 1 in real-time and switches to server 2 if it fails. When the project is small-scale and only one server and several other PCs can be deployed, redundancy method 2 (server redundancy with other PCs) should be selected. In this case, all data on server 1 will be redundant with the first other PC according to a defined rule table, and this PC will continuously monitor server 1, ready to switch over. If a redundancy switch occurs, the second other PC in the rule table will begin synchronizing data with the first other PC and continue monitoring, and so on. All data here is divided into project configuration data and real-time data. Project configuration data includes various configuration parameters (project parameters), internal logical variables (data types and correspondences can be freely created and configured), and functional variables (device function configurations) for the entire project. Real-time data includes real-time acquisition and output point data (DI / DQ / AI / AQ), operation log data (operation records of all buttons except those at the above points), and error logs. The server stores project configuration data and real-time data from all sites; the client synchronously obtains project configuration data and real-time data from other sites in the server database, and stores the real-time data for that site in real time; field stations read and write project configuration data from the server and store the real-time data for that site.

[0084] Figure 5 This is a schematic diagram of the system's real-time data link. For larger-scale projects, there may be a complete system architecture consisting of dual servers, multiple clients, and field stations. In this case, the real-time data link in the system would look like this: Figure 5 As shown, the field station synchronizes real-time data with the equipment, including four types of real-time acquired control data (AI / AQ / DI / AQ). AI and DI represent analog and digital data acquisition, respectively. In addition to communicating with the aforementioned field devices, the field station also interacts with other devices via common industrial communication protocols such as MODBUS RTU / TCP, CAN, and PROFINET. Here, all data in the communication protocols is associated with internal variables in the configuration software. Furthermore, it can communicate with other devices through an OPC server; here, all data acquired by OPC is also associated with internal variables. This variable association can be achieved through the project configuration data table in the database. One client may correspond to multiple field stations, aggregating their real-time data. This data is ultimately aggregated to the server. The real-time synchronization period is configurable, with a maximum speed of 250ms.

[0085] Figure 6 This diagram illustrates the configuration and operation interface of the pump set solenoid valve control model. The configuration monitoring system includes pre-set control models for various rotating machinery applications. When configuring the pump set solenoid valve control model, a model serial number is automatically generated to ensure its uniqueness within the data. Users can then configure variable connections for pump inlet pressure, pump set control, pump inlet solenoid valve, backing pump, Roots pump, and remote / local connections as needed. Note that here, variables from field devices, variables parsed from third-party communication, or user-created internal variables can be selected. Generally, variables from field devices are selected here. Specifically, users also need to configure the pre-set control methods, interlocking controls, and parameters 1-5 to select the pre-set control methods and parameters. The pump set solenoid valve control model mainly includes the following general flow of control methods:

[0086] (1) Pump start-up and shutdown control

[0087] When entering the pump set startup process, first open the solenoid valve, start the back pump after an interval of T1, and then continuously monitor the pump inlet pressure. When the pump inlet pressure is greater than A, start the Roots pump to complete the pump set startup.

[0088] When entering the pump set shutdown process, first shut down the Roots pump, then shut down the back pump after a time interval T2, and then shut down the solenoid valve after a time interval T3, thus completing the pump set shutdown.

[0089] (2) Interlocking start / stop control of the front pump

[0090] When entering the backing pump interlock start / stop procedure, first open the solenoid valve, start the backing pump after an interval of T4, and then continuously monitor the pump inlet pressure. When the pump inlet pressure is greater than (B+C), shut down the backing pump and close the solenoid valve. B is the set condition for shutting down the backing pump, and C is the control dead zone (i.e., the backing pump should be turned on when B is reached, but to prevent damage to the backing pump from frequent start / stop, the backing pump is shut down when the pump inlet pressure is greater than B+C). When the pump inlet pressure is less than (BC), open the solenoid valve, start the backing pump after an interval of T4.

[0091] (3) Pump unit interlock start-stop control

[0092] When entering the pump set interlock start / stop procedure, first monitor the pump inlet pressure. When the pump inlet pressure is less than (DE), first open the solenoid valve, start the backing pump after an interval of T5, and after an interval of T6, start the Roots pump when the pump inlet pressure is greater than F. When the pump inlet pressure is greater than (D+E), shut down the Roots pump, then shut down the backing pump after an interval of T6, close the solenoid valve, and continuously monitor the pump inlet pressure. D is the set condition for shutting down the backing pump, and E is the control dead zone.

[0093] In addition to the three commonly used pump control methods mentioned above, pump control modes with different inlet pressures, time intervals, and logical sequences can also be achieved through control methods and parameter configurations.

[0094] After configuring the pump solenoid valve in the equipment configuration interface, a configuration window will be generated as shown below. Figure 6 The pump solenoid valve control shown in the middle image can be configured via [method / mechanism] during screen setup. Figure 6 The control configuration page shown on the right in the figure allows you to modify various parameters to adapt to the actual needs of the engineering system.

[0095] Figure 7 This is a schematic diagram of the booster pump model configuration and operation interface. When configuring the booster pump control model, a model serial number will be automatically generated to ensure the model's uniqueness in the data. Users can then connect variables for the pump inlet pressure, pump inlet solenoid valve, booster pump, and remote / local connections as needed. Note that here, variables can be selected from field devices, variables parsed from third-party communication, or user-created internal variables. Generally, variables from field devices are selected here. Specifically, users also need to configure preset control methods, interlocking controls, and parameters to select preset control methods and parameters. The booster pump control model mainly implements interlocking control of the booster pump, solenoid valve, and pump inlet pressure. When entering the pump group solenoid valve interlocking control, the pump inlet pressure is monitored first. When the pump inlet pressure is less than (FG), the solenoid valve is opened first, and the booster pump is started after an interval of T7. When the pump inlet pressure is greater than (F+G), the solenoid valve is closed, and the booster pump is shut down after an interval of T8, while the pump inlet pressure is continuously monitored. F represents the set condition for shutting down the upstream pump, and G represents the control dead zone. In addition to the above interlocking control, different control methods, time intervals, and logical sequences for the booster pump solenoid valves can be achieved through control methods and parameter configuration.

[0096] After configuring the booster pump solenoid valve in the equipment configuration interface, a configuration window will be generated as shown below. Figure 7 The booster pump solenoid valve control shown in the middle image can be configured via [method / mechanism] during screen setup. Figure 7 The control configuration page shown on the right in the figure allows you to modify various parameters to adapt to the actual needs of the engineering system.

[0097] Figure 8This is a schematic diagram of the configuration and operation interface of an electrically controlled valve model. When configuring the electrically controlled valve control model, a model serial number will be automatically generated to ensure the model's uniqueness in the data. Users can then link variables as needed for current opening degree, setting opening degree, selecting control, setting step size, self-test control, manual up adjustment, manual down adjustment, manual full open, manual full close, full open state, full close state, upstream pressure, downstream pressure, target pressure, P, I, D, start control, stop control, start state, stop device, self-tuning control, PID control, and remote / local control. Here, variables from field devices, variables parsed from third-party communication, or self-created internal variables can be selected. Generally, variables from field devices are selected here. Specifically, users also need to configure preset control methods. In the electrically controlled valve control model, the main control methods are manual control, PID control, and PID parameter self-tuning. After configuring the electrically controlled valve in the equipment configuration interface, a configuration image like this will be generated during screen configuration. Figure 8 The electrically controlled valve control shown in the middle image can be configured via [method / mechanism] during screen setup. Figure 8 The control configuration page shown on the right in the figure allows you to modify various parameters to adapt to the actual needs of the engineering system.

[0098] Figure 9 This is a schematic diagram of the configuration and operation interface of a pressure solenoid valve model. When configuring the pressure solenoid valve model, a model serial number is automatically generated to ensure its uniqueness in the data. Users can then configure the pressure measuring points and solenoid valves as needed. Here, variables from the field equipment, variables parsed from third-party communication, or self-created internal variables can be selected. Generally, variables from the field equipment are selected here. Specifically, users also need to configure preset control methods, interlocking controls, and parameters to select preset control methods and parameters. The pressure solenoid valve control model mainly implements interlocking control between the pressure measuring points and the solenoid valve. When entering the pressure solenoid valve interlocking control, the pressure measuring point is monitored first. When the pressure before the pump is less than (HI), the solenoid valve is opened. When the pressure before the pump is greater than (H+I), the solenoid valve is closed, and the pressure measuring point is continuously monitored. H is the set condition for closing the upstream pump, and I is the control dead zone. In addition to the above interlocking control, different pressure measuring points, time intervals, and logical sequences of the electrically controlled valve can be implemented through control method and parameter configuration. After configuring the pressure solenoid valve in the device configuration interface, a configuration window will be generated as shown below. Figure 9 The pressure solenoid valve control shown in the middle image can be configured via [method / mechanism] during screen setup. Figure 9 The control configuration page shown on the right in the figure allows you to modify various parameters to adapt to the actual needs of the engineering system.

[0099] Figure 10 This is a schematic diagram of the power supply model configuration and operation interface. When configuring the power control model, a model serial number will be automatically generated to ensure the model's uniqueness in the data. Users can then link variables such as U1-U3, I1-I3, F, active power, reactive power, apparent power, operating status, and fault status as needed. Here, variables from field devices, variables parsed from third-party communication, or user-created internal variables can be selected. Generally, variables from the PLC are selected here. After configuring the power supply model in the device configuration interface, a configuration image like this will be generated during screen configuration. Figure 10 The power control shown in the middle image can be configured via [method / mechanism] during screen setup. Figure 10 The control configuration page shown on the right in the figure allows you to modify various parameters to adapt to the actual needs of the engineering system.

[0100] Figure 11 This is a schematic diagram of the modal test model configuration and operation interface. When configuring the modal test control model, a model serial number will be automatically generated to ensure the model's uniqueness in the data. Users can then link variables for modal acquisition modes, excitation points, response points, start control and status, and stop control and status as needed. Here, variables from field devices, variables parsed from third-party communication, or user-created internal variables can be selected. After configuring the modal test model in the device configuration interface, a configuration window will be generated as shown below. Figure 11 The modal testing control shown in the middle image can be configured via [method / mechanical testing control] during screen setup. Figure 11 The control configuration page shown on the right in the figure allows you to modify various parameters to adapt to the actual needs of the engineering system.

[0101] Figure 12 This is a schematic diagram of the configuration and operation interface for a group module model. When configuring a group module model, a model serial number is automatically generated to ensure the model's uniqueness in the data. Users can then configure the number of modules and link variables as needed. The system automatically calculates maximum, minimum, average, and slip values, and allows modification of upper and lower limits. It also provides a root mean square distribution function. Here, variables from field devices, variables parsed from third-party communication, or user-defined internal variables can be selected. Generally, variables from field devices are selected here. After configuring the electrically adjustable valve in the device configuration interface, a configuration like this will be generated during the screen configuration process. Figure 12 The grouped controls shown can be configured on the screen using... Figure 12 The control configuration page shown on the right in the figure allows you to modify various parameters to adapt to the actual needs of the engineering system.

[0102] Figure 13 Automatically generate flowcharts for the screen.

[0103] In terms of screen generation and development, based on the configuration software, it automatically generates basic screens (including preset controls such as analog and Boolean quantities), special screens (alarms, data queries, trend charts, reports, flowcharts, etc.), and navigation buttons according to computer resolution and generation rules. It supports screen position adjustment, data linking, parameter configuration, deletion, and addition, and has object alignment and distribution capabilities. The screens include basic screens and supporting screens. Basic screens include analog / Boolean quantity modules, special modules such as pump solenoid valves, and standard group modules. Supporting screens include data query, trend chart, alarm, and preset report screens, etc., with the specific steps as follows:

[0104] S1: Obtain system screen resolution parameters, project variables, and the specific number of models.

[0105] S2: Calculate the number of models and the canvas area occupied by a single model.

[0106] S3: Calculate the number of digital and analog quantities other than variables used by the model, and calculate the canvas area occupied by the digital and analog controls.

[0107] S4: Based on the total area occupied by the above screens and the number of various controls, arrange them in the canvas according to the edge distance parameter and control spacing parameter, and calculate the number of basic screens and the number of controls in each screen.

[0108] S5: Add special screens such as alarms, queries, and preset reports after several basic screens.

[0109] S6: Perform manual adjustments to complete the image generation.

[0110] Figure 14This is a schematic diagram of the monitoring system screen. The screen is mainly divided into three parts: a hideable menu bar at the top, a middle page display area containing a movable alarm display button, and a real-time alarm display box that pops up on the right side of the button. The menu bar automatically appears when the mouse hovers over the top of the screen; it hides when the mouse is moved away. The menu bar includes various function buttons. Clicking the "Alarm Display" button brings up the real-time alarm display page on the right, where you can view real-time system alarms and process value alarms. Clicking a single alarm message confirms the alarm. Clicking the function buttons on the menu bar allows you to configure the system for split-screen mode, switch page displays, confirm alarms, query alarm information, report information, log information, and manually fill in logs. Clicking the "Split-Screen Settings" button brings up the split-screen settings; select the split screen and view, and click "OK". The system will then be displayed on another screen, with the default view being the configured view. Clicking the "All Views" button displays a list of all views; clicking the corresponding view button switches to that view. Clicking "Alarm Confirmation" stops the current system alarm sound and changes the alarm message to "Confirmed," which can be viewed in the alarm management section. Click "Report Management" to display printed historical reports, which can be queried or exported. Click "Alarm Management" to display all alarm information, and alarms can be masked or confirmed for individual or multiple systems. Click "Log Management" to view and export all operation records during system operation.

[0111] Figure 15 This is a schematic diagram of the process piping diagram editing interface. When configuring and editing a process piping diagram, the main focus is on describing various instruments, pipes, valves, and other equipment according to the process flow. For example... Figure 15 As shown, this feature provides dynamic indication of the flow direction in the process pipeline. It can mix two substances in the pipeline to create a new substance, which is displayed through color and flow direction. The substances in the pipeline will automatically change dynamically based on the opening and closing of solenoid valves and the pipeline flow rate. The process pipeline flow diagram can also be configured with parameters by clicking on facilities such as solenoid valves and pressure gauges.

[0112] Figure 16 This is a flowchart of the process for switching over redundant servers.

[0113] S1: System initialization. Server 1 and Server 2 complete communication self-test with the host computer and modules, and test whether the heartbeat mechanism is normal.

[0114] S2: Enable redundancy controller function. Both Server 1 and Server 2 are in redundancy mode, and Server 2 continuously monitors Server 1 via Ethernet communication.

[0115] S3: Determine if server 1 has failed. If not, repeat step S3 and wait for server 1 to fail. If it has failed, proceed to step S4.

[0116] S4: Server 2 immediately takes over the engineering system functions and continues to monitor the status of Server 1.

[0117] S5: Determine if server 1 has recovered from the failure. If not, repeat step S5 and wait for server 1 to recover. If yes, proceed to step S6.

[0118] S6: When server 1 recovers from a failure, it does not immediately take over the functions of the engineering system. Instead, it first obtains the latest data through Ethernet communication and continuously updates it to reach and maintain the latest state.

[0119] S7: Server 1 notifies Server 2 to switch controllers via a heartbeat mechanism and immediately takes over the engineering system functions. Server 2 resumes its normal listening state and then proceeds to step S3.

[0120] The present invention has been described above by way of example. It should be noted that any simple modifications, alterations or other equivalent substitutions that can be made by those skilled in the art without creative effort without departing from the core of the present invention fall within the protection scope of the present invention.

Claims

1. A configuration system for monitoring rotating machinery, characterized in that, include: The system configuration module, device management module, screen configuration module, communication service module, data management module, alarm system module, project management module, and user management module are all included. The system configuration module is used to configure the system architecture; The equipment management module is used to manage the equipment configured in the project. It can configure various rotating machinery control models, including: pump group solenoid valve model, booster pump model, electric regulating valve model, pressure solenoid valve model, power supply model, modal test model, and group module model, and configure relevant parameters. The screen configuration module is used to automatically generate basic screens and corresponding alarm screens, trend chart screens, and report screens based on variable attributes and engineering configuration data of associated devices; it provides preset control and custom control functions to allow users to freely combine control elements; The communication service module is used to implement industrial communication functions; The data management module is used to manage engineering configuration data and real-time data; The alarm system module includes three alarm levels: recording, prompting, and alarming, with the severity increasing sequentially. It is mainly divided into two categories: process value alarms and system alarms, and provides audible and visual alarms. The project management module is used to create, query, open, modify, save, and import / export projects during the development process, facilitating the rapid deployment of projects on the rotating machinery site. The user management module is used for role-based access control, providing account password login, permission allocation, and operation log recording.

2. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: Variable attributes include name, type, address, and alarm threshold.

3. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: The basic workflow of a configuration monitoring system Includes the following steps: S1: First, define the system architecture and device parameters through the system configuration module and device management module; S2: Then use the screen configuration module to automatically generate or customize the screen; S3: During runtime, the client communicates with the server to implement data monitoring, alarm, and reporting functions.

4. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: The configuration monitoring system adopts a C / S architecture. Its basic engineering deployment architecture includes several servers, several clients, and several field stations. The servers are used to aggregate data, the clients are used to aggregate data from several field stations, and the field stations are used to interact with the equipment.

5. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: The configuration monitoring system includes a presentation layer, an access layer, a business relationship layer, business support, a data support layer, a storage layer, basic support, and service management. The presentation layer provides screen support for the configuration software and its operation; the access layer uses a Socket interface to manage message queues; and the business relationship layer is used for software authorization, authentication, load and hot standby monitoring. Business support is the functional implementation part of the software, including both configuration and operation aspects. In terms of configuration, it supports data acquisition configuration, variable processing, third-party communication, alarm settings, data processing, and log management. In the operation part, the server provides screen configuration, supporting screens, dynamic flowcharts, data query, and reporting functions, while the client provides screen operation, authorization settings, alarms, and local persistence management functions. The data support layer includes thread pool management, SQL executor, database and table access, file access, device access, acquired data processing, data quality monitoring, MQ access, cache access, and Socket data transmission. The storage layer includes business databases, cache and hot data, client persistence, and module communication. Service management includes running thread monitoring, alarm generation and recovery, client / server data support, and process monitoring.

6. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: The engineering configuration data includes various configuration parameters, internal logical variables, and equipment function variables for the entire project; the real-time data includes real-time acquisition and output point data, operation log data, and error logs.

7. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: The server stores project configuration data and real-time data from all sites; the client synchronously obtains project configuration data and real-time data from other sites from the server database, and stores the real-time data of that site in real time; the field station reads and writes project configuration data from the server and stores the real-time data of that site.

8. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: When configuring the pump set solenoid valve control model, a model serial number is automatically generated to ensure the model's uniqueness in the data. Then, the user can link variables for the pump inlet pressure, pump set control, pump inlet solenoid valve, backing pump, Roots pump, and remote / local settings as needed. The pump set solenoid valve control model includes: pump set start / stop control, backing pump interlock start / stop control, and pump set interlock start / stop control. After configuring the pump set solenoid valve in the equipment configuration interface, a pump set solenoid valve control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

9. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: When configuring the booster pump control model, a model serial number is automatically generated to ensure the model's uniqueness in the data. Then, the user can link variables for the pump inlet pressure, pump inlet solenoid valve, booster pump, and remote / local settings as needed. In the booster pump control model, interlocking control of the booster pump, solenoid valve, and pump inlet pressure is implemented. After configuring the booster pump solenoid valve in the equipment configuration interface, a booster pump solenoid valve control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

10. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: When configuring the electrically controlled valve control model, a model serial number will be automatically generated to ensure the model's uniqueness in the data. Then, the user can link variables as needed for current opening degree, setting opening degree, selected control, setting step size, self-test control, manual up adjustment, manual down adjustment, manual full open, manual full close, full open state, full close state, upstream pressure, downstream pressure, target pressure, P, I, D, self-tuning start control, stop control, start state, stop device, self-tuning control, PID control, and remote / local control. The control methods in the electrically controlled valve control model include manual control, PID control, and PID parameter self-tuning. After configuring the electrically controlled valve in the equipment configuration interface, an electrically controlled valve control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

11. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: When configuring the pressure solenoid valve model, a model serial number will be automatically generated to ensure the model's uniqueness in the data. Then, the user can configure the pressure measuring points and solenoid valves as needed. The pressure solenoid valve control model includes the interlocking control of the pressure measuring points and solenoid valves. After configuring the pressure solenoid valve in the equipment configuration interface, a pressure solenoid valve control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

12. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: When configuring the power control model, a model serial number is automatically generated to ensure the model's uniqueness in the data. Then, the user can link variables for active power, reactive power, apparent power, operating status, and fault status as needed. After configuring the power model in the device configuration interface, a power control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

13. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: When configuring the modal test control model, a model serial number will be automatically generated to ensure the model's uniqueness in the data. Then, the user can link variables for modal acquisition mode, excitation point, response point, start control and status, and stop control and status as needed. After configuring the modal test model in the device configuration interface, a modal test control will be generated during screen configuration. During screen configuration, various parameters can be modified through the control configuration configuration page.

14. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: When configuring the group module model, the model number is automatically generated to ensure the uniqueness of the model in the data; then the user configures the number of units and link variables of the group module as needed, and the maximum, minimum, average and slip values ​​are automatically calculated, and the upper and lower limits are modified and configured.

15. The configuration system for monitoring rotating machinery according to claim 1, characterized in that: The automatic image generation process is as follows: S1: Obtain system screen resolution parameters and the specific number of variables and models within the project; S2: Calculate the number of models and the canvas area occupied by a single model; S3: Calculate the number of digital and analog quantities other than variables used by the model, and calculate the canvas area occupied by the digital and analog quantity controls. S4: Based on the total area occupied by the above screens and the number of various controls, arrange them in the canvas according to the edge distance parameter and control spacing parameter, and calculate the number of basic screens and the number of controls in each screen; S5: Add special screens such as alarms, queries, and preset reports after several basic screens; S6: Perform manual adjustments to complete the image generation.

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