Intelligent monitoring structure for preventing motor damage

Abstract

The utility model discloses an intelligent monitoring structure of preventing motor damage relates to the field of semiconductors. This intelligent monitoring structure of preventing motor damage vibration sensor, PLC controller, communication module, power module, vibration sensor installs on the shell of motor or speed reducer and is used for gathering the vibration signal of motor or speed reducer, and PLC controller is electrically connected with vibration sensor. This intelligent monitoring structure of preventing motor damage through integrated vibration sensor, PLC controller and communication module, realized the on -line real -time analysis and intelligent judgement to motor vibration, can establish or apply benchmark model based on equipment initial operation data fast, through real -time comparison and intelligent analysis, can send early warning in the early stage of failure, realized the change from periodic maintenance to predictive maintenance, the modular integrated design is convenient to install maintenance, finally reaches the purpose of finding hidden danger in advance, avoids non - scheduled shutdown, reduces the capacity loss and maintenance cost.

Description

Technical Field

[0001] This utility model relates to the field of semiconductor technology, specifically to an intelligent monitoring structure for preventing motor damage. Background Technology

[0002] The motor and reducer of the OHT vehicle typically require regular maintenance during long-term use, as their stability directly affects the overall operational stability of the OHT vehicle.

[0003] However, in actual operation, it has been found that some OHT (Outdoor Motor Transporter) vehicles experience occasional motor damage even during regular maintenance, resulting in losses for the company. This is usually due to wear on the bearings of some motors. As the wear increases, the maintenance time decreases. However, current maintenance time relies mainly on visual inspection and judgment, making it impossible to accurately predict the motor's repair and maintenance time. This increases the difficulty of maintenance and the greater the losses after motor failure, often requiring the replacement of the entire motor system, thus increasing the company's losses. To address the shortcomings of existing technology, this invention provides an intelligent monitoring structure to prevent motor damage and solve the above problems. Utility Model Content

[0004] To address the shortcomings of existing technologies, this invention provides an intelligent monitoring structure for preventing motor damage. Through integrated vibration sensors, PLC controllers, and communication modules, it achieves online real-time analysis and intelligent judgment of motor vibration. It can quickly establish or apply benchmark models based on initial equipment operating data. Through real-time comparison and intelligent analysis, it can issue early warnings of faults, realizing the transformation from scheduled maintenance to predictive maintenance. The modular integrated design facilitates installation and maintenance, ultimately achieving the goal of early detection of potential problems, avoiding unplanned downtime, and reducing production capacity loss and maintenance costs.

[0005] To achieve the above objectives, this utility model provides the following technical solution: an intelligent monitoring structure for preventing motor damage, comprising: Vibration sensors are installed on the housing of motors or speed reducers and are used to collect vibration signals from the motors or speed reducers. The PLC controller is electrically connected to the vibration sensor. The PLC controller is used to receive and analyze the vibration signal, compare it with the normal set vibration threshold parameter, and determine whether the motor is abnormal. The communication module is electrically connected to the PLC controller and is used to send the processing results to the host computer. The power supply module provides power to the vibration sensor, PLC controller, and communication module. When the PLC controller detects an abnormal vibration signal, it sends a warning signal to the host computer through the communication module.

[0006] Preferably, the vibration sensor, PLC controller, and communication module are integrated on a circuit board.

[0007] Preferably, the circuit board is detachably fixed to the housing by a mounting bracket.

[0008] Preferably, the mounting bracket is detachably equipped with a protective cover for protecting the vibration sensor, PLC controller and communication module, and the protective cover is provided with a heat dissipation structure.

[0009] Preferably, the circuit board is installed in isolation from the mounting bracket via a gasket.

[0010] Preferably, the power module is a battery or a conversion circuit that draws power from a motor power supply interface.

[0011] Preferably, the communication module is also used to receive control commands issued by the host computer to adjust the sampling frequency of the vibration sensor.

[0012] Preferably, the vibration sensor detects in the same direction as the motor axis or radial direction.

[0013] Preferably, the communication module further includes a local indicator light or alarm, used to issue a visual or audible warning signal on-site when a fault signal is transmitted.

[0014] Preferably, the communication module is a WIFI module and / or a Bluetooth module.

[0015] The technical effects and advantages of this utility model are as follows: This intelligent monitoring structure for preventing motor damage, through integrated vibration sensors, PLC controllers, and communication modules, enables online real-time analysis and intelligent judgment of motor vibration. It can quickly establish or apply benchmark models based on initial equipment operating data, and through real-time comparison and intelligent analysis, it can issue early warnings of faults, realizing the transformation from regular maintenance to predictive maintenance. The modular integrated design facilitates installation and maintenance, ultimately achieving the goal of early detection of potential problems, avoiding unplanned downtime, and reducing production capacity loss and maintenance costs. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the overall installation position of this utility model; Figure 2 This is a schematic diagram of the internal structure of the protective cover of this utility model; Figure 3 This is a schematic diagram of the overall structure of this utility model; Figure 4 This is a schematic diagram of the logic judgment of this utility model; Figure 5 This is a schematic diagram of the vibration sensor of this utility model detecting the fluctuation.

[0018] In the diagram: 1. Vibration sensor; 2. PLC controller; 3. Communication module; 4. Circuit board; 5. Mounting bracket; 51. Protective cover; 52. Gasket; 100. Housing. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0020] This embodiment discloses an intelligent monitoring structure for preventing motor damage, according to the appendix. Figure 1 To be continued Figure 5 As shown, the system includes a vibration sensor 1, a PLC controller 2, a communication module 3, a power supply module, and an installation structure. This intelligent monitoring structure is installed on the housing 100 of the motor or reducer of the OHT vehicle. By continuously monitoring and analyzing vibration signals, it enables intelligent monitoring and early warning of the motor's health status.

[0021] According to the appendix Figure 1 As shown, the vibration sensor 1, PLC controller 2, and communication module 3 are integrated on a single circuit board 4, forming a compact intelligent monitoring unit. The circuit board 4 is detachably fixed to the housing 100 of the motor or reducer via a mounting bracket 5. The mounting position is preferably near key vibration sources such as motor bearings or reducer output ends to obtain more sensitive vibration signals.

[0022] According to the appendix Figure 2As shown, to further protect the internal electronic components and adapt to industrial environments, a protective cover 51 is detachably mounted on the mounting bracket 5. The protective cover 51 is equipped with heat dissipation structures, such as heat dissipation holes or heat dissipation fins, to ensure that the module can effectively dissipate heat in a closed environment, preventing component performance degradation or damage due to high temperatures. The circuit board 4 is isolated from the metal mounting bracket 5 by an insulating gasket 52. This design effectively avoids potential electrical interference or short-circuit risks between the circuit board 4 and the mounting bracket 5.

[0023] According to the appendix Figure 1 With appendix Figure 3 As shown, the vibration sensor 1 is configured to detect vibrations in the same direction as the motor's axial or radial direction to specifically capture characteristic vibrations caused by faults such as motor rotational imbalance, bearing wear, and abnormal gear meshing. The PLC controller 2 is electrically connected to the vibration sensor 1 and is used to receive and analyze the raw vibration signals collected by the sensor in real time. Its core functions include signal filtering and feature extraction, such as vibration acceleration, effective velocity value, and spectral components. The extracted feature values ​​are then compared with an internally stored "health state" standard vibration model established through AI learning or with set vibration threshold parameters.

[0024] According to the appendix Figure 3 With appendix Figure 4 As shown, the communication module 3 is electrically connected to the PLC controller 2. When the PLC controller 2 analyzes the vibration signal and determines that its characteristics deviate from the healthy model or exceed the warning threshold, it indicates a potential abnormality or accelerated wear in the motor or reducer. At this time, the PLC controller 2 generates a warning signal and sends it to the host computer, such as a workshop central monitoring system, via the communication module 3. The communication module 3 is preferably a WIFI module and / or a Bluetooth module to enable wireless data transmission, facilitating deployment in complex FAB plant environments. Furthermore, the communication module 3 can also be used to receive control commands from the host computer, such as remotely adjusting the vibration signal sampling frequency of the vibration sensor 1 to adapt to different operating stages or varying diagnostic accuracy requirements.

[0025] According to the appendix Figure 2 With appendix Figure 3 As shown, the power module is used to power the entire intelligent monitoring structure. The power module can be a built-in rechargeable or disposable battery for independent power supply; or it can be a voltage conversion circuit connected to the motor power supply interface to safely draw power from the motor's main power supply, ensuring that the monitoring system operates synchronously with the motor.

[0026] According to the appendix Figure 2 With appendix Figure 3As shown, the communication module 3 can also integrate local indicator lights or a small alarm. When the PLC controller 2 determines a fault and generates a warning signal, in addition to sending information to the host computer, it can also drive the local indicator lights to flash or the alarm to sound, providing intuitive visual or auditory warnings on site, making it easier for inspection personnel to quickly locate abnormal equipment.

[0027] According to the appendix Figure 1 To be continued Figure 4 As shown, it is particularly important to emphasize that the analysis and judgment logic of PLC controller 2 in this structure is a continuous learning and optimization process. During initial installation or after major overhaul of the motor or reducer, the system collects normal operating vibration data for a preset period. PLC controller 2 uses its built-in AI algorithm to train and analyze this data, autonomously establishing a unique "healthy" vibration characteristic baseline or model for the equipment, and setting dynamic warning thresholds. Subsequent continuous monitoring is based on this personalized model for comparison, thereby improving the accuracy and lead time of fault prediction.

[0028] Especially public, such as Figure 5 As shown, Figure 5 This is a schematic diagram of the vibration sensor of this utility model detecting the fluctuation. When the motor fails and stops, the vibration monitoring parameters in the early stage show a clear upward trend until the motor fails and stops in the final stage. Therefore, this utility model can provide early warning of motor failure, intervene in advance, reduce the degree of motor damage, and improve the motor life.

[0029] Example 1: This example uses early warning of initial wear of motor bearings as an example, combined with the attached... Figure 1 To be continued Figure 5 Detailed explanation of its workflow: The circuit board 4, which integrates the vibration sensor 1, PLC controller 2, and communication module 3, is fixed to the housing of the new motor using a mounting bracket 5. After the system is powered on, the communication module 3 connects to the factory's WIFI network and registers with the host computer.

[0030] The motor begins normal operation. Vibration sensor 1 collects axial and radial vibration signals at a set frequency. PLC controller 2 continuously collects data for several weeks, and uses AI algorithms to learn and construct a vibration spectrum characteristic model and normal vibration amplitude range of the motor in a healthy state, which serves as a benchmark for subsequent judgments.

[0031] The system enters the routine monitoring phase. PLC controller 2 analyzes the vibration signals from vibration sensor 1 in real time. If PLC controller 2 detects a sustained, slow increase in the energy of high-frequency components in the vibration spectrum, and although the overall effective vibration value does not exceed the hard shutdown threshold, it significantly deviates from the previously established health model, PLC controller 2 determines it as an "abnormality of potential bearing wear." It immediately sends a warning signal to the host computer via communication module 3, including the device ID, abnormality type, and degree of deviation. Simultaneously, the local indicator light begins flashing a yellow warning. Upon receiving the signal, the host computer system generates a maintenance work order, notifying maintenance personnel to inspect the motor during the planned shutdown period. Upon arrival, maintenance personnel quickly locate the device using the indicator lights.

[0032] Upon inspection, if the motor bearing did indeed show early fatigue pitting, the factory was able to replace the bearing in the next planned maintenance cycle due to the early warning, thus avoiding serious losses such as motor burnout and unexpected production line interruption caused by sudden bearing seizure.

[0033] Example 2: This example uses remote centralized monitoring and adaptive adjustment as an example, combined with the appendix... Figure 1 To be continued Figure 5 Detailed explanation of its workflow: This intelligent monitoring structure is installed on the motors of multiple trolleys throughout the entire OHT track system.

[0034] All monitoring units transmit real-time vibration data or characteristic values ​​to the central host computer via communication module 3. The host computer software not only receives alarms but also performs big data analysis, compares the operating status of similar motors, and identifies general risks or batch problems.

[0035] Engineers discovered through the host computer that the OHT vehicles in a certain area required more intensive monitoring due to load changes. Therefore, they sent a command through the host computer to the communication module 3 of all monitoring units in that area, increasing the sampling frequency of their vibration sensors 1 from 1kHz to 5kHz to obtain a more refined vibration spectrum for analysis.

[0036] The system continuously records every warning, inspection result, and maintenance record. Combined with AI models, the host computer can continuously optimize warning thresholds and even predict the remaining useful life (RUL), providing accurate data support for the factory's predictive maintenance (PdM) strategy and achieving an upgrade from "prevention" to "prediction".

[0037] Finally, it should be noted that the above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An intelligent monitoring structure for preventing motor damage, characterized in that, include: A vibration sensor (1) is installed on the housing (100) of a motor or reducer and is used to collect vibration signals from the motor or reducer. The PLC controller (2) is electrically connected to the vibration sensor (1), and the PLC controller (2) is used to receive and analyze vibration signals; The communication module (3) is electrically connected to the PLC controller (2) and is used to send the processing results to the host computer; The power supply module provides power to the vibration sensor (1), PLC controller (2) and communication module (3); When the PLC controller (2) detects an abnormal vibration signal, it sends a warning signal to the host computer through the communication module (3).

2. The intelligent monitoring structure for preventing motor damage according to claim 1, characterized in that, The vibration sensor (1), PLC controller (2) and communication module (3) are integrated on the circuit board (4). The PLC controller (2) analyzes the received vibration signal and compares it with the normal set vibration threshold parameter to determine whether the motor is abnormal.

3. The intelligent monitoring structure for preventing motor damage according to claim 2, characterized in that, The circuit board (4) is detachably fixed to the housing (100) by a mounting bracket (5).

4. The intelligent monitoring structure for preventing motor damage according to claim 3, characterized in that, The mounting bracket (5) is detachably mounted with a protective cover (51) for protecting the vibration sensor (1), PLC controller (2) and communication module (3), and the protective cover (51) is provided with a heat dissipation structure.

5. The intelligent monitoring structure for preventing motor damage according to claim 3, characterized in that, The circuit board (4) is installed in isolation from the mounting bracket (5) via a gasket (52).

6. The intelligent monitoring structure for preventing motor damage according to claim 1, characterized in that, The power module is a conversion circuit that draws power from a battery or through a motor power supply interface.

7. The intelligent monitoring structure for preventing motor damage according to claim 1, characterized in that, The communication module (3) is also used to receive control commands from the host computer to adjust the sampling frequency of the vibration sensor (1).

8. The intelligent monitoring structure for preventing motor damage according to claim 1, characterized in that, The vibration sensor (1) detects in the same direction as the motor axis or radial direction.

9. The intelligent monitoring structure for preventing motor damage according to claim 1, characterized in that, The communication module (3) also includes a local indicator light or alarm, which is used to issue a visual or audible warning signal on site when a fault signal is transmitted.

10. The intelligent monitoring structure for preventing motor damage according to claim 1, characterized in that, The communication module (3) is a WIFI module and / or a Bluetooth module.

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