CN109720814B - Remote fault monitoring and diagnosing system for belt conveyor - Google Patents
Remote fault monitoring and diagnosing system for belt conveyor Download PDFInfo
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Abstract
The invention discloses a remote fault monitoring and diagnosing system for a belt conveyor, which comprises a field end and a remote end, wherein the field end is connected with the remote end; the field terminal includes: field sensors and DCS systems; the remote end includes: a remote server and a diagnostic terminal; the DCS comprises an upper computer and a lower computer which are connected; the field sensor is connected with the lower computer; the upper computer is communicated with the remote server through a configuration script file; the remote server communicates with the diagnostic terminal. The invention integrates all parts of the belt conveyor to be detected on site, and enables remote expert personnel to remotely monitor and diagnose the operation of the belt conveyor and remotely guide the personnel on site through unified acquisition, uploading, storage and remote access, thereby improving the operation efficiency of the system, reducing the occurrence frequency of accidents, prolonging the service life of equipment and reducing the operation and maintenance cost of enterprises.
Description
Technical Field
The invention relates to a belt conveyor fault monitoring and diagnosing system suitable for the fields of electric power, steel, coal, water conservancy, chemical industry, metallurgy, building materials and the like, in particular to a belt conveyor remote fault monitoring and diagnosing system.
Background
At present, belt conveyor wide application in fields such as electric power, steel, coal, water conservancy, chemical industry, metallurgy, building materials, meanwhile, belt conveyor system is developing to the upsizing direction of high belt speed, high power, heavy traffic and long distance, but along with belt conveyor system equipment body to the upsizing direction development, following main problems have appeared in traditional belt conveyor monitored control system:
1. and the subsystems are mutually independent on site, and the integration level is low.
2. The failure information can not be predicted and predicted, and only the occurred failure can be manually checked and remedied by adopting measures.
3. The manual inspection mode is adopted to manage and maintain the equipment, the workload of personnel is large, the efficiency is low, the misjudgment rate is high, and the cost is high.
Therefore, how to realize the remote analysis and diagnosis of the belt conveyor system and remotely guide field personnel, thereby improving the operation efficiency of the system, reducing the occurrence frequency of accidents, prolonging the service life of equipment and reducing the operation and maintenance cost of enterprises is a practical problem that enterprises want to solve.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: aiming at the existing problems, the remote fault monitoring and diagnosing system for the belt conveyor can realize remote real-time online monitoring of field equipment data, predict and pre-judge the possible fault information and remotely analyze and diagnose the fault information.
The technical scheme adopted by the invention is as follows:
a remote fault monitoring and diagnosing system for a belt conveyor comprises a field end and a remote end; the field terminal includes: field sensors and DCS systems; the remote end includes: a remote server and a diagnostic terminal; the DCS comprises an upper computer and a lower computer which are connected; the field sensor is connected with the lower computer; the upper computer is communicated with the remote server through a configuration script file; the remote server is communicated with the diagnosis terminal;
the field sensor is arranged at a position needing to be detected of the belt conveyor; the DCS collects real-time detection data of the field sensor through the lower computer, generates a fault alarm signal according to the real-time detection data, and then sends the real-time detection data and the fault alarm signal to the remote server through the upper computer; and the diagnosis terminal accesses the real-time detection data and the fault alarm signal in the remote server through a network.
Preferably, the remote server is provided with a database server, an intelligent analysis processing platform and a WEB server;
the intelligent analysis processing platform is used for generating a chart or a trend curve according to the real-time detection data and generating a report according to the fault alarm signal;
the database server is used for storing the real-time detection data, the trend curve, the fault alarm signal and the report;
and the WEB server is used for pushing the real-time detection data, the trend curve, the fault alarm signal and the report to a browser.
Preferably, the diagnosis terminal accesses real-time detection data, a trend curve, a fault alarm signal and a report form in the remote server through a browser.
Preferably, the workflow of the script file is as follows:
step 1, accessing a WEB server through an upper computer, configuring and selecting real-time detection data and fault alarm signals which need to be sent to a remote server, and forming a configuration file after configuration is completed;
step 2, checking whether the variable names of the real-time detection data and the fault alarm signals in the upper computer are consistent with the variable names in the configuration file; if the two are consistent, executing the step 3, and if the two are not consistent, reporting an error prompt;
step 3, judging whether variable values exist in the variable names of the real-time detection data and the fault alarm signals in the upper computer; if the variable value exists, the variable value is copied to the same variable name in the configuration file, and then the variable value in the configuration file is sent to the remote server.
Preferably, the field sensor comprises a protection switch, a tension detector, a vibration monitor, a temperature sensor and an electrical signal detector.
Preferably, the protection switch comprises a pull switch, a deviation switch, a slipping switch, a tearing-proof switch, a material blocking switch, a limit switch and a pressure switch.
Preferably, the tension detector is mounted on a steel wire rope of the belt conveyor and used for detecting the stress of the steel wire rope.
Preferably, the vibration monitors are respectively arranged on the bases of the motor and the reducer of the belt conveyor and around the bearing housing and are used for measuring the vibration displacement of the motor and the reducer in the X-Y-Z directions.
Preferably, the temperature sensors are mounted on a winding and a bearing of a motor of the belt conveyor and a bearing of the speed reducer, and respectively measure the temperature of the winding and the bearing of the motor and the temperature of the bearing of the speed reducer.
Preferably, the electrical signal detected by the electrical signal detector comprises: voltage signals, current signals, power signals, torque signals, speed signals, and frequency signals.
In summary, due to the adoption of the technical scheme, the invention has the beneficial effects that:
by adopting the remote fault monitoring and diagnosing system for the belt conveyor, all parts needing to be detected of a plurality of belt conveyors on site can be integrated, and remote expert personnel can remotely monitor and diagnose the operation of the belt conveyor and remotely guide the personnel on site through unified acquisition, uploading, storage and remote access, so that the operating efficiency of the system is improved, the accident occurrence frequency is reduced, the service life of equipment is prolonged, and the operation and maintenance cost of enterprises is reduced.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
FIG. 1 is a block diagram of the system of the present invention.
Fig. 2 is a block diagram of a remote server system of the present invention.
FIG. 3 is a flowchart illustrating the operation of the script file according to the present invention.
Reference numerals: 10-field end, 11-field sensor, 12-DCS system, 20-remote end, 21-remote server, 211-database server, 212-intelligent analysis processing platform, 213-WEB server, and 22-diagnosis terminal.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the present invention without making any creative effort, shall fall within the protection scope of the present invention.
It is to be noted that the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.
The features and properties of the present invention are described in further detail below with reference to examples.
Example 1
A remote fault monitoring and diagnostic system for a belt conveyor, as shown in fig. 1, includes a field terminal (10) and a remote terminal 20; the site end 10 includes: a field sensor 11 and a DCS system 12; the remote terminal 20 includes: a remote server 21 and a diagnostic terminal 22; the DCS 12 comprises an upper computer and a lower computer which are connected with each other; the field sensor 11 is connected with the lower computer; the upper computer is communicated with a remote server 21 through a configuration script file; the remote server 21 communicates with a diagnostic terminal 22. The field sensor 11 is connected with the lower computer through a cable.
In the adopted DCS, the lower computer mainly comprises a CPU and an I/O module and is used for acquiring real-time detection data of the field sensor 11 and generating a fault alarm signal according to the real-time detection data; the upper computer is an operation management station and comprises a display screen, a power supply, a CPU, a communication interface, a storage module and upper computer software, wherein the storage module is used for storing the real-time detection data and generating a fault alarm signal; the display screen displays a field data interface. And the upper computer sends the real-time detection data and the fault alarm signal to the remote server. Preferably, the transmission protocol between the upper computer and the remote server 21 is http protocol.
The remote server 21 adopts a Daire PowerEdge R430 host and is configured with redundant double power supplies. As shown in fig. 2, the remote server 21 is provided with a database server 211, an intelligent analysis processing platform 212 and a WEB server 213; the intelligent analysis processing platform 212 is used for generating a chart or a trend curve according to the real-time detection data and generating a report according to the fault alarm signal; the database server 211 is configured to store the real-time detection data, the trend curve, the fault alarm signal, and the report; and the WEB server 213 is used for pushing the real-time detection data, the trend curve, the fault alarm signal and the report to a browser.
After the DCS system and the remote server are connected to each other through hardware, data transmission can be performed only by configuring a script file, as shown in fig. 3, the specific work flow is as follows:
step 1, accessing a WEB server through an upper computer, configuring and selecting real-time detection data and fault alarm signals which need to be sent to a remote server, and forming a configuration file after configuration is completed; in practical application, all data do not need to be transmitted at any time, and if all data are transmitted, a large amount of bandwidth and a storage hard disk are occupied, so that the bandwidth utilization rate can be reduced through configuration selection, and the system operation efficiency is improved.
Step 2, checking whether the variable names of the real-time detection data and the fault alarm signals in the upper computer are consistent with the variable names in the configuration file; if the two are consistent, executing the step 3, and if the two are not consistent, reporting an error prompt;
step 3, judging whether variable values exist in the variable names of the real-time detection data and the fault alarm signals in the upper computer; if the variable value exists, the variable value is copied to the same variable name in the configuration file, and then the variable value in the configuration file is sent to the remote server.
The on-site sensor 11 installed at a position to be detected of the belt conveyor includes a protection switch, a tension detector, a vibration monitor, a temperature sensor and an electric signal detector. The protection switch comprises a pull switch, a deviation switch, a slipping switch, an anti-tearing switch, a material blocking switch, a limit switch and a pressure switch and is used for feeding back whether the field equipment is abnormal in operation; the tension detector is arranged on a steel wire rope of the belt conveyor and used for detecting the stress of the steel wire rope. The vibration monitor is respectively arranged on the motor of the belt conveyor, the base of the speed reducer and the periphery of the bearing shell and is used for measuring the vibration displacement of the motor and the speed reducer in the X-Y-Z directions. The temperature sensors are arranged on a winding and a bearing of a motor of the belt conveyor and a bearing of the speed reducer and respectively measure the temperature of the winding and the bearing of the motor and the temperature of the bearing of the speed reducer. The electrical signal detected by the electrical signal detector comprises: voltage signals, current signals, power signals, torque signals, rotational speed signals, and frequency signals, which may be collected and transmitted by a frequency converter. The lower computer collects the switching value data of the protection switch in real time and the analog quantity data of the tension detector, the vibration monitor, the temperature sensor and the electric signal detector, the analog quantity adopts a 4-20mA current signal, and a fault alarm signal is generated by combining a built-in control program according to the change conditions of the switching value data and the analog quantity data, and meanwhile, timely protection actions such as shutdown can be performed.
The diagnostic terminal 22 accesses the real-time detection data, the trend curve, the fault alarm signal and the report in the remote server 21 through a network. Specifically, the diagnosis terminal 22 is a PC connected with a display through a VGA cable, and the display is preferably 55 inches in order to facilitate viewing of so much data. The remote expert uses a PC to access the real-time detection data, the trend curve, the fault alarm signal and the report form in the remote server 21 through a browser, remotely diagnoses the belt conveyor, and remotely feeds back the diagnosis result to relevant personnel of the on-site enterprise through mails or short messages. Different decision rules are established for different signal types of the real-time detection data, for example: after the belt conveyor reaches a rated rotating speed, recording the rotating speed difference of the two motors in real time through a remote fault monitoring and diagnosing system, and generating a chart or a trend curve; and the remote expert predicts the possible future unexpected situations according to the variation trend of the difference of the rotating speeds of the two motors and feeds back the guidance suggestions to relevant personnel of the on-site enterprise. If the difference between the rotation speeds of the two motors is gradually increased but does not exceed the allowable set value, the wear condition of the roller corresponding to the motor with the higher rotation speed needs to be closely concerned, and the roller corresponding to the motor with the lower rotation speed is seriously worn, so that a repair or replacement plan needs to be made in advance. And giving different solutions to the report generated by the fault alarm signal according to different signal types and types. For example, the remote fault monitoring and diagnosis system records the pull-cord fault, and the remote expert can prompt the field personnel to determine whether the personnel operates, check whether the pull-cord switch is damaged, whether the line is damaged or interfered, and the like.
By adopting the remote fault monitoring and diagnosing system for the belt conveyor, all parts of the belt conveyor on site, which need to be detected, can be integrated, and remote expert personnel can remotely monitor and diagnose the operation of the belt conveyor through unified acquisition, uploading, storage and remote access and remotely guide the personnel on site, so that the operating efficiency of the system is improved, the accident occurrence frequency is reduced, the service life of equipment is prolonged, and the operating and maintaining cost of enterprises is reduced.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (8)
1. A remote fault monitoring and diagnosing system for a belt conveyor is characterized by comprising a field end (10) and a remote end (20); the site end (10) comprises: a field sensor (11) and a DCS system (12); the remote end (20) comprises: a remote server (21) and a diagnostic terminal (22); the DCS system (12) comprises an upper computer and a lower computer which are connected with each other; the field sensor (11) is connected with the lower computer; the upper computer is communicated with a remote server (21) through a configuration script file; the remote server (21) communicates with a diagnostic terminal (22);
the on-site sensor (11) is arranged at a position needing to be detected of the belt conveyor; the DCS (12) acquires real-time detection data of the field sensor (11) through the lower computer, generates a fault alarm signal according to the real-time detection data, and then sends the real-time detection data and the fault alarm signal to the remote server (21) through the upper computer; the diagnostic terminal (22) accesses the real-time detection data and the fault alarm signal in the remote server (21) through a network;
the remote server (21) is provided with a database server (211), an intelligent analysis processing platform (212) and a WEB server (213);
the intelligent analysis processing platform (212) is used for generating a chart or a trend curve according to the real-time detection data and generating a report according to the fault alarm signal;
the database server (211) is used for storing the real-time detection data, the trend curve, the fault alarm signal and the report;
the WEB server (213) is used for pushing the real-time detection data, the trend curve, the fault alarm signal and the report to a browser;
the upper computer is an operation management station and comprises a display screen, a power supply, a CPU, a communication interface, a storage module and upper computer software, wherein the storage module is used for storing the real-time detection data and generating a fault alarm signal; the display screen displays a field data interface;
the workflow of the script file is as follows:
step 1, accessing a WEB server through an upper computer, configuring and selecting real-time detection data and fault alarm signals which need to be sent to a remote server, and forming a configuration file after configuration is completed;
step 2, checking whether the variable names of the real-time detection data and the fault alarm signals in the upper computer are consistent with the variable names in the configuration file; if the two are consistent, executing the step 3, and if the two are not consistent, reporting an error prompt;
step 3, judging whether variable values exist in the variable names of the real-time detection data and the fault alarm signals in the upper computer; if the variable value exists, the variable value is copied to the same variable name in the configuration file, and then the variable value in the configuration file is sent to the remote server.
2. The remote belt conveyor fault monitoring and diagnosis system of claim 1, wherein the diagnostic terminal accesses real-time detection data, trend curves, fault alarm signals and reports in the remote server (21) through a browser.
3. The belt conveyor remote fault monitoring and diagnostic system of claim 1, wherein the field sensors (11) include a protection switch, a tension detector, a vibration monitor, a temperature sensor, and an electrical signal detector.
4. The remote belt conveyor fault monitoring and diagnosis system of claim 3, wherein the protection switches include a pull switch, a tracking switch, a skid switch, a tear switch, a jam switch, a limit switch, and a pressure switch.
5. The system of claim 3, wherein the tension detector is mounted on a wire rope of the belt conveyor for detecting the stress of the wire rope.
6. The system of claim 3, wherein the vibration monitor is mounted around the base and bearing housing of the motor and reducer of the belt conveyor, respectively, for measuring the vibration displacement of the motor and reducer in X-Y-Z directions.
7. The remote belt conveyor fault monitoring and diagnosis system of claim 3, wherein the temperature sensors are mounted on the windings and bearings of the motor of the belt conveyor and the bearings of the reducer to measure the temperature of the windings and bearings of the motor and the bearings of the reducer, respectively.
8. The belt conveyor remote fault monitoring and diagnostic system of claim 3, wherein the electrical signal detected by the electrical signal detector comprises: voltage signals, current signals, power signals, torque signals, speed signals, and frequency signals.
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| CN112037500A (en) * | 2020-07-21 | 2020-12-04 | 江苏国茂减速机股份有限公司 | Speed reducer capable of automatically judging fault, elevator and fault automatic judging method |
| CN111977310A (en) * | 2020-07-24 | 2020-11-24 | 甘肃酒钢集团宏兴钢铁股份有限公司 | A comprehensive protection method for long-distance belt conveyor |
| CN119100089B (en) * | 2024-10-23 | 2025-04-25 | 淮北合众机械设备有限公司 | Intelligent detection system based on remote operation and maintenance |
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