CN117851956A - Electromechanical equipment fault diagnosis method, system and terminal based on data analysis - Google Patents
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Abstract
The invention discloses an electromechanical equipment fault diagnosis method, system and terminal based on data analysis, which relate to the technical field of electromechanical equipment fault diagnosis and comprise the following steps: obtaining each maintenance time of the electromechanical equipment according to the equipment maintenance recordCalculating to obtain the change rate of the maintenance timeBwx，And further calculate to obtain estimated maintenance timeGw；Collecting vibration signals of electromechanical equipment, and analyzing the vibration signals of normal operation and vibration signals to be detected to obtain abnormal vibration coefficientsZy；Obtaining the length of each damaged use of each componentTime to start useAnd real timeSj，Calculating to obtain failure index of each part. The abnormal condition can be detected before the equipment has obvious faults while unnecessary detection and data processing are reduced, the abnormal parts can be accurately positioned, and the faults are prevented from being enlarged or serious consequences are caused.
Description
Technical Field
The invention relates to the technical field of electromechanical equipment fault diagnosis, in particular to an electromechanical equipment fault diagnosis method, system and terminal based on data analysis.
Background
With the rapid development of industrial technology, electromechanical devices play an increasingly important role in numerous fields. The stable operation of these devices is critical to ensure the continuity and efficiency of the production line. However, electromechanical devices may fail for a variety of reasons, such as long-term operation of the device, improper maintenance, or environmental factors. Therefore, developing an efficient and accurate fault diagnosis method has important significance for reducing equipment downtime, reducing maintenance cost and improving production efficiency.
In the chinese application of the application publication No. CN115840915a, an automatic method, system, terminal and storage medium for identifying faults of an electromechanical device are disclosed, including obtaining an actual fault phenomenon of the electromechanical device when the electromechanical device fails; acquiring a preset scheme database comprising theoretical fault phenomena, fault components and fault reasons; acquiring a preset cause probability table, wherein the cause probability table comprises fault components and occurrence probability values of each fault cause corresponding to the fault components; matching the actual fault phenomenon with the theoretical fault phenomenon, and obtaining corresponding fault components serving as predictive fault components; acquiring a fault reason corresponding to a predicted fault component as a predicted reason; the predicted reasons are ranked based on the reason probability table, and the ranked reasons are obtained.
In the above application, when the equipment fails, the equipment can be overhauled and removed in time, so that the equipment can work normally as timely as possible, but the equipment is still stopped after the equipment fails, thus influencing the execution of the production plan, and certain equipment failures can involve safety risks, for example, mechanical failures can lead to injury of operators, and if the equipment is not removed in time after the failure, the probability of safety accidents is increased.
Therefore, the invention provides an electromechanical equipment fault diagnosis method, system and terminal based on data analysis.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides an electromechanical equipment fault diagnosis method, system and terminal based on data analysis. The production interruption caused by the sudden shutdown of the equipment can be obviously reduced, and the requirement of emergency maintenance is avoided, so that the technical problem recorded in the background technology is solved.
In order to achieve the above purpose, the invention is realized by the following technical scheme: the electromechanical equipment fault diagnosis method based on data analysis comprises the following steps:
obtaining each maintenance time of the electromechanical equipment according to the equipment maintenance recordCalculating to obtain the change rate of the maintenance timeBwx，And further calculate to obtain estimated maintenance timeGw，When the maintenance time is estimatedGwWhen the first mechanical equipment maintenance early warning value is larger than a preset first threshold value, the first mechanical equipment maintenance early warning value is sent outwards;
when the first electromechanical equipment maintenance early warning is received, the vibration signals of the electromechanical equipment are collected, and the normal operation vibration signals and the vibration signals to be detected are analyzed to obtain abnormal vibration coefficientsZy，Coefficient of vibration anomalyZyGreater than 1.2When the system is in a working state, a second electromechanical maintenance early warning is sent outwards>Representing all vibration anomaly coefficientsZyAverage value of (2);
when the second electromechanical maintenance early warning is received, the time length of each damage use of each component is obtainedStart of use time->And real timeSj，Calculating to obtain failure index of each part>And issues a part failure warning corresponding to the part number to the outside.
Further, obtaining maintenance time of the electromechanical equipment each time according to the equipment maintenance recordAfter linear normalization processing, calculating to obtain maintenance time change rateBwx：
；
Wherein,ia time sequence number indicating each maintenance time,when->In the time-course of which the first and second contact surfaces,。
further, the production and delivery time of the electromechanical equipment is obtained according to the equipment use recordStart of use time->Actual operating time->Real timeSjAnalyzing the change rate of the repair time and the repair time respectively>Is to obtain a maintenance correlation coefficient +.>、/>Is->：
；
Wherein,jrepresenting the sequential numbering of all electromechanical devices,，nis a positive integer; />In (a)cIndicating the production and delivery time of the electromechanical equipment and the samesIndicate the start time +.>，yRepresenting the actual running time; />Representing the maintenance time change rate of all electromechanical devices>Average value of (2).
Further, obtaining maintenance time of the electromechanical equipmentReal time->Rate of change of maintenance timeBwxAnd maintenance related coefficient->、/>Is->After linear normalization processing, calculating to obtain estimated maintenance timeGw：
；
When the maintenance time is estimatedGw>Sj-100And when the first electromechanical equipment is in maintenance early warning, the first electromechanical equipment is sent outwards.
Further, when the first electromechanical equipment maintenance early warning is received, the vibration signals of the electromechanical equipment are acquired through the vibration sensor, the normal operation vibration signals and the vibration signals to be detected of the electromechanical equipment are acquired, the time domain signals are converted into frequency domain signals through Fourier transformation, the frequency range is divided into N equal parts, and the width of each equal part isObtaining the amplitude of the normal operation vibration signal and the vibration signal to be measured in each frequency equal part under the frequency>And->And the number of frequency points in the frequency equal part +.>And->。
Further, the amplitude of the vibration signal which is normally operated in each frequency equal part and the amplitude of the vibration signal to be measured under the frequency are obtainedAnd->And the number of frequency points in the frequency equal part +.>And->After linear normalization processing, calculating to obtain abnormal vibration coefficientZy：
；
Wherein,kindicating the corresponding sequential numbering of each frequency aliquot, ，ais a positive integer;
further, when the vibration abnormality coefficientZyGreater than 1.2When the system is in a working state, a second electromechanical maintenance early warning is sent outwards>Representing all vibration anomaly coefficientsZyAverage value of (2).
Further, the time of each damage of each component is obtainedAfter the linear normalization process, the damage time change rate of each component is calculated>：
；
Wherein,indicating the sequential numbering of the various components of the electromechanical device,xsequential number indicating the duration of use of the component per damage, < >>When->When (I)>。
Further, the starting use time of each component of the current electromechanical equipment is obtainedReal timeSjAnd the rate of change of the failure time of the respective components +.>After linear normalization, the failure index of each part is calculated>：
；
When the failure index of a partIf the number is greater than 0.8, the possibility of failure of the part is high, and a part failure warning corresponding to the part number is issued.
An electromechanical device fault diagnosis system based on data analysis, comprising:
preliminary maintenance prediction module for obtaining each maintenance time of electromechanical equipment according to equipment maintenance recordCalculating to obtain the change rate of the maintenance timeBwx，And further calculate to obtain estimated maintenance timeGw，When the maintenance time is estimatedGwWhen the first mechanical equipment maintenance early warning value is larger than a preset first threshold value, the first mechanical equipment maintenance early warning value is sent outwards;
the maintenance confirmation module is used for collecting vibration signals of the electromechanical equipment when receiving the maintenance early warning of the first electromechanical equipment and analyzing the normal operation vibration signals and the vibration signals to be detected to obtain abnormal vibration coefficientsZy，Coefficient of vibration anomalyZyGreater than 1.2When the system is in a working state, a second electromechanical maintenance early warning is sent outwards>Representing all vibration anomaly coefficientsZyAverage value of (2);
the part confirmation module acquires the damage time of each part when receiving the second electromechanical maintenance early warningStart of use time->And real timeSj，Calculating to obtain failure index of each part>And issues a part failure warning corresponding to the part number to the outside.
The electromechanical equipment fault diagnosis terminal based on data analysis at least comprises a receiving and transmitting unit, a processing unit, a storage unit and a data interface.
The invention provides a fault diagnosis method, a fault diagnosis system and a fault diagnosis terminal for electromechanical equipment based on data analysis, which have the following beneficial effects:
1. obtaining each maintenance time of the electromechanical equipment according to the equipment maintenance recordCalculating to obtain the change rate of the maintenance timeBwx，And further calculate to obtain estimated maintenance timeGw，When the maintenance time is estimatedGwWhen the detection result is larger than a preset first threshold value, the first electromechanical equipment maintenance early warning is sent outwards, unnecessary detection and data processing can be reduced, and hardware and software cost required for storing and processing data is reduced.
2. When the first electromechanical equipment maintenance early warning is received, the vibration signals of the electromechanical equipment are collected, and the normal operation vibration signals and the vibration signals to be detected are analyzed to obtain abnormal vibration coefficientsZy，Coefficient of vibration anomalyZyGreater than 1.2And when the equipment is in an obvious fault, the abnormal condition can be detected before the equipment is in an obvious fault by sending out a second electromechanical maintenance early warning, and the fault is prevented from being enlarged or serious consequences are caused.
3. When the second electromechanical maintenance early warning is received, the time length of each damage use of each component is obtainedStart of use time->And real timeSj，Calculating to obtain failure index of each part>And part fault warning corresponding to the part number is sent outwards, and specific fault components can be accurately positioned, so that a fault source can be quickly and accurately found, the whole equipment is prevented from being disassembled and comprehensively checked, and the maintenance efficiency is improved.
Drawings
FIG. 1 is a flow chart of an electromechanical device fault diagnosis method based on data analysis according to the present invention;
FIG. 2 is a schematic diagram of a fault diagnosis system for an electromechanical device based on data analysis according to the present invention;
fig. 3 is a schematic structural diagram of the fault diagnosis terminal for electromechanical equipment based on data analysis.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, the invention provides a fault diagnosis method for electromechanical equipment based on data analysis, which comprises the following steps:
technical problems: materials of equipment may fail due to aging, corrosion, fatigue and other factors, so that equipment components are damaged, and faults are caused;
step one, obtaining maintenance time of electromechanical equipment each time according to equipment maintenance recordsCalculating to obtain the change rate of the maintenance timeBwx，And further calculate to obtain estimated maintenance timeGw，When the maintenance time is estimatedGwAnd when the maintenance warning value is larger than a preset first threshold value, the maintenance warning of the first electromechanical equipment is sent outwards.
The first step comprises the following steps:
step 101, obtaining each maintenance time of the electromechanical equipment according to the equipment maintenance recordAfter linear normalization processing, calculating to obtain maintenance time change rateBwx：
；
Wherein,ia time sequence number indicating each maintenance time,when->In the time-course of which the first and second contact surfaces,。
102, obtaining the production and delivery time of the electromechanical equipment according to the equipment use recordStart of use time->Actual operating time->Real timeSjAnalyzing the change rate of the repair time and the repair time respectively>Is to obtain a maintenance correlation coefficient +.>、/>Is->：
；
Wherein,jrepresenting the sequential numbering of all electromechanical devices,，nis a positive integer; />In (a)cIndicating the production and delivery time of the electromechanical equipment and the samesIndicate the start time +.>，yRepresenting the actual running time; />Representing the maintenance time change rate of all electromechanical devices>Average value of (2).
Step 103, obtaining maintenance time of the electromechanical equipmentReal time->Rate of change of maintenance timeBwxAnd maintenance related coefficient->、/>Is->After linear normalization processing, calculating to obtain estimated maintenance timeGw：
；
When the maintenance time is estimatedAnd (i.e. a first threshold value) sending out a first electromechanical device maintenance early warning, wherein the time unit is hours.
In use, the contents of steps 101 to 103 are combined:
obtaining each maintenance time of the electromechanical equipment according to the equipment maintenance recordCalculating to obtain the change rate of the maintenance timeBwx，And further calculate to obtain estimated maintenance timeGw，When the maintenance time is estimatedGwWhen the detection result is larger than a preset first threshold value, the first electromechanical equipment maintenance early warning is sent outwards, unnecessary detection and data processing can be reduced, and hardware and software cost required for storing and processing data is reduced.
Step two, when the maintenance early warning of the first electromechanical equipment is received, collecting vibration signals of the electromechanical equipment, and analyzing the normal operation vibration signals and the vibration signals to be detected to obtain abnormal vibration coefficientsZy，Coefficient of vibration anomalyZyGreater than 1.2When the system is in operation, a second electromechanical maintenance early warning is sent outwards,/>representing all vibration anomaly coefficientsZyAverage value of (2).
The second step comprises the following steps:
step 201, when a first electromechanical device maintenance early warning is received, acquiring a vibration signal of the electromechanical device through a vibration sensor, acquiring a vibration signal for normal operation of the electromechanical device and a vibration signal to be tested, converting a time domain signal into a frequency domain signal by using fourier transform, dividing a frequency range into N equal parts, wherein the width of each equal part isObtaining the amplitude of the normal operation vibration signal and the vibration signal to be measured in each frequency equal part under the frequency>And->And the number of frequency points in the frequency equal part +.>And->。
Step 202, obtaining the amplitude values of the vibration signal and the vibration signal to be measured under the frequency in each frequency equal partAnd->And the number of frequency points in the frequency equal part +.>And->After linear normalization processing, calculating to obtainCoefficient of vibration abnormalityZy：
；
Wherein,kindicating the corresponding sequential numbering of each frequency aliquot, ，ais a positive integer.
Coefficient of vibration anomalyZyGreater than 1.2When the system is in a working state, a second electromechanical maintenance early warning is sent outwards>Representing all vibration anomaly coefficientsZyAverage value of (2).
In use, the contents of steps 201 and 202 are combined:
when the first electromechanical equipment maintenance early warning is received, the vibration signals of the electromechanical equipment are collected, and the normal operation vibration signals and the vibration signals to be detected are analyzed to obtain abnormal vibration coefficientsZy，Coefficient of vibration anomalyZyGreater than 1.2And when the equipment is in an obvious fault, the abnormal condition can be detected before the equipment is in an obvious fault by sending out a second electromechanical maintenance early warning, and the fault is prevented from being enlarged or serious consequences are caused.
Step three, when receiving the second electromechanical maintenance early warning, obtaining the time length of each damage use of each componentStart of use time->And real timeSj，Calculating to obtain failure index of each part>And issues a part failure warning corresponding to the part number to the outside.
The third step comprises the following steps:
step 301, obtaining the time length of each damage of each componentAfter the linear normalization process, the damage time change rate of each component is calculated>：
；
Wherein,indicating the sequential numbering of the various components of the electromechanical device,xsequential number indicating the duration of use of the component per damage, < >>When->When (I)>。
Step 302, obtaining the starting time of each component of the current electromechanical deviceReal timeSjAnd the rate of change of the failure time of the respective components +.>After linear normalization, the failure index of each part is calculated>：
；
When the failure index of a partIf the number is greater than 0.8, the possibility of failure of the part is high, and a part failure warning corresponding to the part number is issued.
In use, the contents of steps 301 and 302 are combined:
when the second electromechanical maintenance early warning is received, the time length of each damage use of each component is obtainedStart of use time->And real timeSj，Calculating to obtain failure index of each part>And part fault warning corresponding to the part number is sent outwards, and specific fault components can be accurately positioned, so that a fault source can be quickly and accurately found, the whole equipment is prevented from being disassembled and comprehensively checked, and the maintenance efficiency is improved.
Referring to fig. 2, the present invention provides an electromechanical device fault diagnosis system based on data analysis, including:
preliminary maintenance prediction module for obtaining each maintenance time of electromechanical equipment according to equipment maintenance recordCalculating to obtain the change rate of the maintenance timeBwx，And further calculate to obtain estimated maintenance timeGw，When the maintenance time is estimatedGwAnd when the maintenance warning value is larger than a preset first threshold value, the maintenance warning of the first electromechanical equipment is sent outwards.
The maintenance confirmation module is used for collecting vibration signals of the electromechanical equipment when receiving the maintenance early warning of the first electromechanical equipment and analyzing the normal operation vibration signals and the vibration signals to be detected to obtain abnormal vibration coefficientsZy，Coefficient of vibration anomalyZyGreater than 1.2When the system is in a working state, a second electromechanical maintenance early warning is sent outwards>Representing all vibration anomaly coefficientsZyAverage value of (2).
The part confirmation module acquires the damage time of each part when receiving the second electromechanical maintenance early warningStart of use time->And real timeSj，Calculating to obtain failure index of each part>And issues a part failure warning corresponding to the part number to the outside.
Referring to fig. 3, the invention provides an electromechanical device fault diagnosis terminal based on data analysis, which at least comprises a transceiver unit, a processing unit, a storage unit, a data interface and the like.
The above embodiments may be implemented in whole or in part by software, hardware, firmware, or any other combination. When implemented in software, the above-described embodiments may be implemented in whole or in part in the form of a computer program product. Those of ordinary skill in the art will appreciate that the various illustrative elements and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, or combinations of computer software and electronic hardware. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the solution.
The units described as separate units may or may not be physically separate, and units shown as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
The foregoing is merely specific embodiments of the present application, but the scope of the present application is not limited thereto, and any person skilled in the art can easily think about changes or substitutions within the technical scope of the present application, and the changes and substitutions are intended to be covered by the scope of the present application.
Claims (10)
1. The electromechanical equipment fault diagnosis method based on data analysis is characterized by comprising the following steps of: the method comprises the following steps:
obtaining each maintenance time of the electromechanical equipment according to the equipment maintenance recordCalculating to obtain the change rate of the maintenance timeBwx，And further calculate to obtain estimated maintenance timeGw，When the maintenance time is estimatedGwWhen the first mechanical equipment maintenance early warning value is larger than a preset first threshold value, the first mechanical equipment maintenance early warning value is sent outwards;
when the first electromechanical equipment maintenance early warning is received, the vibration signals of the electromechanical equipment are collected, and the normal operation vibration signals and the vibration signals to be detected are analyzed to obtain abnormal vibration coefficientsZy，Coefficient of vibration anomalyZyGreater than 1.2When the system is in a working state, a second electromechanical maintenance early warning is sent outwards>Representing all vibration anomaly coefficientsZyAverage value of (2);
when the second electromechanical maintenance early warning is received, the time length of each damage use of each component is obtainedTime to start useAnd real timeSj，Calculating to obtain failure index of each part>And issues a part failure warning corresponding to the part number to the outside.
2. The data analysis-based electromechanical device fault diagnosis method according to claim 1, wherein:
obtaining each maintenance time of the electromechanical equipment according to the equipment maintenance recordAfter linear normalization processing, calculating to obtain maintenance time change rateBwx：
；
Wherein,ia time sequence number indicating each maintenance time,when->In the time-course of which the first and second contact surfaces,。
3. the data analysis-based electromechanical device fault diagnosis method according to claim 2, wherein:
obtaining the production and delivery time of the electromechanical equipment according to the equipment use recordStart of use time->Duration of actual operationReal timeSjAnalyzing the change rate of the repair time and the repair time respectively>Is to obtain a maintenance correlation coefficient +.>、Is->The mode is as follows:
；
wherein,jrepresenting the sequential numbering of all electromechanical devices,，nis a positive integer; />In (a)cIndicating the production and delivery time of the electromechanical equipment and the samesIndicate the start time +.>，yRepresenting the actual running time; />Representing the maintenance time change rate of all electromechanical devices>Average value of (2).
4. A method for diagnosing a failure of an electromechanical device based on data analysis as recited in claim 3, wherein:
obtaining maintenance time of electromechanical equipmentReal time->Rate of change of maintenance timeBwxAnd maintenance related coefficient->、/>AndAfter linear normalization processing, calculating to obtain estimated maintenance timeGw：
；
When the maintenance time is estimatedAnd when the first electromechanical equipment is in maintenance early warning, the first electromechanical equipment is sent outwards.
5. The method for diagnosing a fault in an electromechanical device based on data analysis as recited in claim 4, wherein:
when the first electromechanical equipment maintenance early warning is received, the vibration signals of the electromechanical equipment are acquired through the vibration sensor, the normal operation vibration signals and the vibration signals to be detected of the electromechanical equipment are acquired, the time domain signals are converted into frequency domain signals through Fourier transformation, the frequency range is divided into N equal parts, and the width of each equal part isEach frequency is acquiredThe amplitude of the vibration signal which normally operates in the equal ratio and the vibration signal to be measured under the frequency is +.>And->And the number of frequency points in the frequency equal part +.>And->。
6. The method for diagnosing a failure of an electromechanical device based on data analysis according to claim 5, wherein:
obtaining the amplitude of the vibration signal and the vibration signal to be measured under the frequency in each frequency equal partAnd->And the number of frequency points in the frequency equal part +.>And->After linear normalization processing, calculating to obtain abnormal vibration coefficientZy：
；
Wherein,kindicating the corresponding sequential numbering of each frequency aliquot, ，ais a positive integer.
7. The data analysis-based electromechanical device fault diagnosis method according to claim 6, wherein:
obtaining the length of each damaged use of each componentAfter the linear normalization process, the damage time change rate of each component is calculated>：
；
Wherein,indicating the sequential numbering of the various components of the electromechanical device,xsequential numbering representing the length of time the component is used for each break,when->When (I)>。
8. The data analysis-based electromechanical device fault diagnosis method according to claim 7, wherein:
obtaining the starting time of each component of the current electromechanical equipmentReal timeSjAnd the rate of change of the failure time of the respective components +.>After linear normalization, the failure index of each part is calculated>：
；
When the failure index of a partAnd if the number is more than 0.8, part fault warning corresponding to the part number is sent outwards.
9. The electromechanical equipment fault diagnosis system based on data analysis is characterized in that: comprising the following steps:
preliminary maintenance prediction module for obtaining each maintenance time of electromechanical equipment according to equipment maintenance recordCalculating to obtain the change rate of the maintenance timeBwx，And further calculate to obtain estimated maintenance timeGw，When the maintenance time is estimatedGwWhen the first mechanical equipment maintenance early warning value is larger than a preset first threshold value, the first mechanical equipment maintenance early warning value is sent outwards;
the maintenance confirmation module is used for collecting vibration signals of the electromechanical equipment when receiving the maintenance early warning of the first electromechanical equipment and analyzing the normal operation vibration signals and the vibration signals to be detected to obtain abnormal vibration coefficientsZy，Coefficient of vibration anomalyZyGreater than 1.2When the system is in a working state, a second electromechanical maintenance early warning is sent outwards>Representing all vibration anomaly coefficientsZyAverage value of (2);
the part confirmation module acquires the damage time of each part when receiving the second electromechanical maintenance early warningStart of use time->And real timeSj，Calculating to obtain failure index of each part>And issues a part failure warning corresponding to the part number to the outside.
10. An electromechanical device fault diagnosis terminal based on data analysis, for performing the method according to any of claims 1-8, characterized in that: the device at least comprises a receiving and transmitting unit, a processing unit, a storage unit and a data interface.
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| CN118276498A (en) * | 2024-06-03 | 2024-07-02 | 中润华谷(南京)科技有限公司 | Safety control method and system for industrial control Internet of things equipment |
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