Concrete plant fault detection device
By installing multi-parameter detection modules and remote early warning mechanisms on concrete equipment, multi-dimensional real-time monitoring and dual early warning of the equipment are achieved, which solves the shortcomings of manual inspection in existing technologies and improves the safety and production efficiency of the equipment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZUNYI ZHIYUE CONCRETE CO LTD
- Filing Date
- 2025-08-25
- Publication Date
- 2026-08-04
AI Technical Summary
The existing fault monitoring methods for concrete equipment mainly rely on manual periodic inspections, which have problems such as poor real-time performance, strong subjectivity, and many blind spots. In addition, the existing automated equipment cannot fully reflect the equipment status and lacks remote early warning functions, resulting in untimely fault handling and affecting production safety and efficiency.
A fault detection device for concrete equipment was designed, including a fault detection mechanism and a remote early warning mechanism. The device collects parameters such as current, temperature and pressure of key components in real time through a multi-parameter detection module, and achieves dual early warning both locally and remotely by combining a wireless communication module. It has data visualization and delay processing functions to ensure timely detection and handling of faults.
It enables multi-dimensional real-time monitoring of concrete equipment, reduces the risk of misjudgment, ensures equipment safety and production efficiency, supports rapid local and remote response and handling, and prevents the escalation of faults.
Smart Images
Figure CN224593995U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of concrete production equipment monitoring technology, specifically to a concrete equipment fault detection device. Background Technology
[0002] With the acceleration of urbanization and the advancement of infrastructure construction, the demand for concrete, as a core building material, has been increasing year by year, leading to a significant increase in the operating load of concrete production equipment (such as mixing plants, pumps, pavers, etc.). The core components of concrete equipment (such as drive motors, rotary bearings, hydraulic systems, and conveyor belts) are subjected to high load, high dust, and high vibration conditions for extended periods, making them prone to malfunctions such as motor overload, bearing overheating and wear, abnormal hydraulic pressure, and conveyor belt misalignment.
[0003] Current fault monitoring methods for concrete equipment mainly rely on regular manual inspections: workers judge the equipment's condition by observing its appearance, listening to its operating sounds, and manually measuring its temperature. This method has significant drawbacks: First, the long inspection intervals make real-time monitoring difficult. If a fault occurs suddenly (such as a motor short circuit or a hydraulic line rupture), the optimal time for handling it may be missed, leading to equipment damage, production interruption, or even safety accidents. Second, manual judgment relies on experience, is highly subjective, and is prone to omissions and misjudgments (e.g., slight overheating of bearings is difficult to detect by touch). Third, some critical components of the equipment (such as the internal parts of the hydraulic circuit and motor) are difficult to inspect directly by hand, resulting in monitoring blind spots.
[0004] Furthermore, existing automated monitoring equipment only detects a single parameter (such as motor current), failing to comprehensively reflect the overall operating status of the equipment and lacking remote early warning capabilities. When equipment malfunctions during unattended periods (such as nighttime mixing operations), management personnel cannot be informed in a timely manner, further amplifying the impact of the failure. Therefore, developing a device capable of real-time, multi-dimensional monitoring of concrete equipment operating status, with both local and remote early warning capabilities, is of great significance for ensuring production safety, reducing equipment failure rates, and improving production efficiency. Utility Model Content
[0005] To address the shortcomings of existing technologies, this utility model aims to provide a concrete equipment fault detection device that can achieve real-time, multi-dimensional monitoring of the operating status of key components of concrete equipment, promptly detect potential faults and trigger dual local and remote early warnings, prevent the fault from escalating, and ensure production safety and efficiency.
[0006] To solve the above problems, the technical solution provided by this utility model is: a concrete equipment fault detection device, including a fault detection mechanism and a remote early warning mechanism;
[0007] The fault detection mechanism includes a first controller, a multi-parameter detection module, a first display, a first alarm module, and a first communication module; the multi-parameter detection module is installed on the concrete equipment and is used to collect the operating parameters of the concrete equipment; the first controller is electrically connected to the multi-parameter detection module, the first display, the first alarm module, and the first communication module respectively.
[0008] The remote early warning mechanism includes a second controller, a second display, a second alarm module, and a second communication module; the second controller is electrically connected to the second display, the second alarm module, and the second communication module respectively.
[0009] The fault detection mechanism and the remote early warning mechanism are connected via a first communication module and a second communication module.
[0010] The principle and beneficial effects of this solution are as follows:
[0011] 1. Multi-dimensional real-time monitoring: Through multi-parameter detection modules (covering key components such as motors, bearings, hydraulics, and conveyor belts), core operating parameters such as current, temperature, pressure, and displacement are collected to comprehensively reflect the operating status of concrete equipment, solving the problems of many blind spots, strong subjectivity, and incomplete monitoring of single parameters under traditional manual inspection.
[0012] 2. Dual local and remote early warning: When the parameters exceed the limit, the first controller of the fault detection mechanism first displays the fault parameters visually on the first display, and then triggers the first alarm module (audio-visual prompt) to remind the on-site operators; if the fault is not handled in time, it can also send a signal to the remote early warning mechanism through the first communication module. The second controller at the remote end drives the second display to display the fault information and triggers the second alarm module to remind the management personnel, realizing a closed loop of on-site response and remote control, and avoiding the omission of faults during unattended periods;
[0013] 3. Data visualization: Both the first and second displays can show the equipment's operating parameters in real time, allowing operators and managers to intuitively grasp the equipment's status without relying on experience-based judgment, thus reducing the risk of misjudgment.
[0014] Furthermore, the multi-parameter detection module includes a motor current sensor, a bearing temperature sensor, a hydraulic pressure sensor, and a conveyor belt displacement sensor. The motor current sensor is installed on the power supply circuit of the drive motor of the concrete equipment; the bearing temperature sensor is fixedly attached to the surface of the rotating bearing of the concrete equipment; the hydraulic pressure sensor is connected to the hydraulic oil circuit of the concrete equipment; and the conveyor belt displacement sensor is installed on the side of the conveyor belt of the concrete equipment. Sensors are deployed for the four core components most prone to failure in concrete equipment (motor, bearing, hydraulic system, and conveyor belt). The motor current sensor monitors overload risk, the bearing temperature sensor monitors wear and overheating, the hydraulic pressure sensor monitors oil circuit leaks or blockages, and the conveyor belt displacement sensor monitors belt misalignment, ensuring the targeted and effective nature of the monitoring.
[0015] Furthermore, both the first and second communication modules are wireless communication modules; the wireless communication modules include one or more of the following: WiFi module, Bluetooth module, LoRa module, and ZigBee module. Wireless communication eliminates the need for wiring, adapting to the complex wiring environments of concrete production sites (such as mixing plants and construction sites), and supports multiple networking methods. The WiFi module is suitable for high-speed transmission over short distances (such as within a factory area), while the LoRa module is suitable for low-power transmission over long distances (such as across construction sites), improving the device's environmental adaptability.
[0016] Furthermore, both the first and second alarm modules include warning lights and buzzers; the warning lights are tri-color LEDs, corresponding to normal, warning, and fault operating states respectively. This triple alert of sound, light, and color avoids omissions caused by a single alert method: green indicates normal operation, yellow indicates parameters are approaching the threshold (warning), and red indicates parameters are exceeding limits (fault). The buzzer emits different frequencies for warnings and faults, allowing operators and managers to quickly identify the equipment's status level.
[0017] Furthermore, the fault detection mechanism also includes a delay module electrically connected to the first controller. This delay module is used to delay the triggering of the first alarm module and the remote early warning signal for a preset time after the operating parameters collected by the multi-parameter detection module exceed a preset threshold. This avoids false alarms caused by instantaneous fluctuations. When concrete equipment starts up or the load changes (such as at the moment of material feeding into the mixing tank), parameters may briefly exceed the threshold. The delay module (with a preset time of 3-5 seconds) can filter out such instantaneous fluctuations, triggering an alarm only when the parameters continuously exceed the standard, reducing unnecessary early warning interference.
[0018] Furthermore, the first controller is also used to compare the operating parameters collected by the multi-parameter detection module with preset thresholds to determine the fault type and corresponding component, and send the fault type and component information to the first and second displays for display. The first controller automatically identifies the faulty component and type by parameter type (such as excessive current corresponding to the motor, excessive temperature corresponding to the bearing), and clearly marks it on the display (such as "motor overload", "bearing overheating", etc.). Operators do not need to check parameters one by one, and can directly deal with the faulty component, improving fault handling efficiency. Attached Figure Description
[0019] Figure 1 This is a logic block diagram of an embodiment of the concrete equipment fault detection device of this utility model.
[0020] Figure 2 This is a logic block diagram of the fault detection mechanism in an embodiment of this utility model. Detailed Implementation
[0021] The following detailed description illustrates the specific implementation method:
[0022] The basic implementation examples are as follows: Figure 1 and attached Figure 2 As shown, the concrete equipment fault detection device includes a fault detection mechanism and a remote early warning mechanism;
[0023] The fault detection mechanism includes a first controller, a multi-parameter detection module, a first display, a first alarm module, and a first communication module; the multi-parameter detection module is installed on the concrete equipment and is used to collect the operating parameters of the concrete equipment; the first controller is electrically connected to the multi-parameter detection module, the first display, the first alarm module, and the first communication module respectively.
[0024] The remote early warning mechanism includes a second controller, a second display, a second alarm module, and a second communication module; the second controller is electrically connected to the second display, the second alarm module, and the second communication module respectively.
[0025] The fault detection mechanism and the remote early warning mechanism are connected via a first communication module and a second communication module.
[0026] In the fault detection mechanism of this embodiment: the first controller adopts the STM32H7 series high-performance microcontroller, specifically the STM32H743VIT6, with a main frequency of 480MHz. It has a multi-channel ADC acquisition interface and a UART communication interface, and can simultaneously receive 4 sensor signals and drive peripherals. It is responsible for data processing, logic judgment and instruction sending.
[0027] The multi-parameter detection module includes a motor current sensor, a bearing temperature sensor, a hydraulic pressure sensor, and a conveyor belt displacement sensor. The motor current sensor is an ACS712 model with a range of 0-30A. It is connected to the power supply circuit of the concrete equipment drive motor (such as the mixer drive motor), and acquires the motor operating current through the Hall effect, outputting a 0-5V analog signal to the ADC interface of the first controller, an STM32H743VIT6 microcontroller. The bearing temperature sensor is a DS18B20 model with a temperature range of -55℃ to 125℃. It is fixed to the end cover of the rotating bearing (such as the mixer shaft bearing) with high-temperature thermally conductive adhesive. The sensor leads are protected by a metal bellows to prevent corrosion by concrete slurry, and output a digital signal to the first... The controller is an STM32H743VIT6 microcontroller. The hydraulic pressure sensor is a model MPX5700 with a range of 0-700kPa. It is connected to the oil circuit flange of the hydraulic system (such as the hydraulic oil circuit of the delivery pump) through a threaded interface, collects the real-time oil circuit pressure, and outputs a 0-3.3V analog signal to the first controller STM32H743VIT6 microcontroller. The conveyor belt displacement sensor is a model GP2Y0A21YK, which uses laser ranging and has a detection distance of 10-80cm. It is fixed to the side of the conveyor belt (such as the frame of a concrete conveyor belt) with an L-shaped bracket. The laser emitter is aligned with the edge of the conveyor belt, collects the displacement difference between the conveyor belt and the bracket baseline, and outputs an analog signal to the first controller STM32H743VIT6 microcontroller.
[0028] The first display uses a 2.4-inch TFT LCD screen with a resolution of 320*240, which displays various parameter values and fault information in real time.
[0029] The first alarm module includes a three-color LED light (green / yellow / red) and a buzzer (frequency adjustable, 1kHz for warning and 2kHz for fault).
[0030] The first communication module is a wireless communication module, which uses an ESP8266 WiFi module (supporting 802.11b / g / n protocol) and a LoRa module (model SX1278, transmission distance 1-3km), and the two modules can be switched.
[0031] The fault detection mechanism also includes a delay module electrically connected to the first controller; the delay module is used to delay the first alarm module and remote early warning signal transmission for a preset time after the operating parameters collected by the multi-parameter detection module exceed the preset threshold. The delay module uses a timer built into the STM32H743VIT6 microcontroller of the first controller, and the delay time is set to 5 seconds.
[0032] The fault detection mechanism also includes a protective shell made of ABS engineering plastic with a waterproof rating of IP65. It has internal heat dissipation holes to accommodate the first controller, the first display, the first alarm module, and the first communication module. The surface of the protective shell has a display window and a buzzer sound hole.
[0033] In the remote early warning mechanism of this embodiment: the second controller adopts an STM32F1 series microcontroller, specifically the STM32F103C8T6, which is responsible for receiving remote signals, driving the display and alarm.
[0034] The second display uses a 7-inch touchscreen (800*480 resolution) and can simultaneously display various parameter values and fault information of multiple concrete equipment.
[0035] The second alarm module has the same structure as the first alarm module, including a three-color LED light (green / yellow / red) and a buzzer (frequency adjustable, 1kHz for warning and 2kHz for fault).
[0036] The second communication module is matched with the first communication module, using a WiFi module (model ESP8266, supporting 802.11b / g / n protocol) and a LoRa module (model SX1278, transmission distance 1-3km). The WiFi module is suitable for high-speed transmission over short distances (such as within a factory area), while the LoRa module is suitable for low-power transmission over long distances (such as across construction sites). The two modules can be switched to ensure communication compatibility.
[0037] The remote early warning system is integrated and deployed in the control room console or the manager's office.
[0038] The specific workflow of this embodiment is as follows:
[0039] 1. Parameter acquisition and judgment:
[0040] The multi-parameter detection module collects data in real time. Among them, the motor current sensor collects the working current of the drive motor, the bearing temperature sensor collects the surface temperature of the rotating bearing, the hydraulic pressure sensor collects the working pressure of the hydraulic oil circuit, and the conveyor belt displacement sensor collects the displacement difference between the edge of the conveyor belt and the baseline.
[0041] The first controller receives various parameter signals and compares them with preset thresholds (which can be manually set via the first display, such as motor current threshold 25A, bearing temperature threshold 80℃, hydraulic pressure threshold 600kPa, and conveyor belt displacement threshold 5cm):
[0042] If the parameters are within the normal range: the first display shows green, indicating a normal state, and the parameter values are updated in real time; the first alarm module does not activate. If the parameters are close to the threshold (e.g., current 23-25A or temperature 75-80℃): the first display shows yellow, indicating a warning state; the yellow LED of the first alarm module illuminates, and the buzzer emits an intermittent 1kHz sound. If the parameters exceed the threshold: the first controller activates the delay module and continuously monitors the parameters for 5 seconds. If the parameters return to normal within 5 seconds, the warning is canceled. If the parameters still exceed the limit after 5 seconds, it is determined to be a fault state, and the first display shows red.
[0043] 2. Local alarm and remote transmission:
[0044] In the fault state, the first display shows red, indicating the fault state, and marks the faulty component (such as "motor overload") and the parameter exceeding the standard (such as "current 28A"). The red LED of the first alarm module is constantly lit, and the buzzer emits a continuous 2kHz sound.
[0045] The first controller sends a fault signal to the remote early warning agency through the first communication module (selecting either a WiFi module or a LoRa module based on the distance; for example, in this embodiment, the deployment distance between the fault detection agency and the remote early warning agency is 600m, so a WiFi module is selected). The signal includes the device number, the faulty component, the parameters exceeding the standard, and the time of the fault occurrence.
[0046] After receiving the fault signal, the second communication module transmits it to the second controller; the second controller drives the second display to show the fault information (such as "Mixing plant No. 1 motor overload, current 28A, 7-26 14:30"), the red LED of the second alarm module stays on, and the buzzer emits a continuous 2kHz sound.
[0047] 3. Troubleshooting and Reset:
[0048] After receiving a local alarm, on-site operators can view detailed fault information on the first display and take targeted measures (such as stopping the machine to check the motor, replacing the bearings, cleaning the hydraulic circuit, and adjusting the conveyor belt).
[0049] After the fault was cleared and the parameters returned to normal, the first controller automatically canceled the local alarm and sent a "fault cleared" signal to the remote early warning mechanism. The second controller canceled the remote alarm, cleared the fault information on the second display, the green LED of the second alarm module remained on, and the buzzer was turned off.
[0050] If the problem is not addressed on-site in a timely manner, management personnel can view the location of the faulty equipment through a second monitor and remotely coordinate personnel to handle it, thus preventing the problem from escalating.
[0051] The above are merely embodiments of this utility model. This utility model is not limited to the field covered by this embodiment. Commonly known structures and characteristics in the solution are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are able to access all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, under the guidance of this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of this utility model. These should also be considered within the scope of protection of this utility model, and will not affect the effectiveness of the implementation of this utility model or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims. The specific embodiments described in the specification can be used to interpret the content of the claims.
Claims
1. A concrete equipment fault detection device, characterized in that: This includes fault detection agencies and remote early warning agencies; The fault detection mechanism includes a first controller, a multi-parameter detection module, a first display, a first alarm module, and a first communication module; the multi-parameter detection module is installed on the concrete equipment and is used to collect the operating parameters of the concrete equipment; the first controller is electrically connected to the multi-parameter detection module, the first display, the first alarm module, and the first communication module respectively. The remote early warning mechanism includes a second controller, a second display, a second alarm module, and a second communication module; the second controller is electrically connected to the second display, the second alarm module, and the second communication module respectively. The fault detection mechanism and the remote early warning mechanism are connected via a first communication module and a second communication module.
2. The concrete equipment fault detection device according to claim 1, characterized in that: The multi-parameter detection module includes a motor current sensor, a bearing temperature sensor, a hydraulic pressure sensor, and a conveyor belt displacement sensor. The motor current sensor is installed on the power supply circuit of the drive motor of the concrete equipment. The bearing temperature sensor is attached and fixed to the surface of the rotating bearing of the concrete equipment. The hydraulic pressure sensor is connected to the hydraulic oil circuit of the concrete equipment. The conveyor belt displacement sensor is installed on the side of the conveyor belt of the concrete equipment.
3. The concrete equipment fault detection device according to claim 1, characterized in that: Both the first communication module and the second communication module are wireless communication modules; the wireless communication module includes one or more of the following: WiFi module, Bluetooth module, LoRa module, and ZigBee module.
4. The concrete equipment fault detection device according to claim 1, characterized in that: Both the first alarm module and the second alarm module include a warning light and a buzzer; the warning light is a three-color LED light, which corresponds to three operating states: normal, warning, and fault.
5. The concrete equipment fault detection device according to claim 1, characterized in that: The fault detection mechanism also includes a delay module electrically connected to the first controller; The delay module is used to delay the first alarm module and the remote early warning signal transmission for a preset time after the operating parameters collected by the multi-parameter detection module exceed the preset threshold.
6. The concrete equipment fault detection device according to claim 1, characterized in that: The first controller is also used to compare the operating parameters collected by the multi-parameter detection module with preset thresholds to determine the fault type and corresponding component, and send the fault type and component information to the first display and the second display for display.