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WO2020134890A1 - 一种用于运转设备运行数据安康监测的振动温度传感器 - Google Patents

一种用于运转设备运行数据安康监测的振动温度传感器 Download PDF

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Publication number
WO2020134890A1
WO2020134890A1 PCT/CN2019/122515 CN2019122515W WO2020134890A1 WO 2020134890 A1 WO2020134890 A1 WO 2020134890A1 CN 2019122515 W CN2019122515 W CN 2019122515W WO 2020134890 A1 WO2020134890 A1 WO 2020134890A1
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WIPO (PCT)
Prior art keywords
module
vibration
temperature sensor
operating
data processing
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PCT/CN2019/122515
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English (en)
French (fr)
Inventor
沈新荣
徐华锋
柴秋子
付立
李创
许丹丹
Original Assignee
杭州哲达科技股份有限公司
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Publication of WO2020134890A1 publication Critical patent/WO2020134890A1/zh

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D21/00—Measuring or testing not otherwise provided for
    • G01D21/02—Measuring two or more variables by means not covered by a single other subclass
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
    • G01H17/00—Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves, not provided for in the preceding groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66B—ELEVATORS; ESCALATORS OR MOVING WALKWAYS
    • B66B5/00—Applications of checking, fault-correcting, or safety devices in elevators
    • B66B5/0006—Monitoring devices or performance analysers
    • B66B5/0018—Devices monitoring the operating condition of the elevator system
    • B66B5/0031—Devices monitoring the operating condition of the elevator system for safety reasons
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
    • G01K13/00—Thermometers specially adapted for specific purposes
    • G—PHYSICS
    • G08—SIGNALLING
    • G08C—TRANSMISSION SYSTEMS FOR MEASURED VALUES, CONTROL OR SIMILAR SIGNALS
    • G08C17/00—Arrangements for transmitting signals characterised by the use of a wireless electrical link
    • G08C17/02—Arrangements for transmitting signals characterised by the use of a wireless electrical link using a radio link

Definitions

  • the invention belongs to the field of intelligent control, and in particular relates to a vibration temperature sensor used for the monitoring of the operating data safety of the operating equipment, which is mainly used for monitoring the operating data of the operating equipment.
  • Operating equipment includes operating equipment and rotating equipment, which are widely used in daily production and life.
  • the car frame of the equipment car is a supporting frame of the car body, which is composed of a cross beam, a column, a bottom beam and a diagonal rod.
  • the car body is composed of a car bottom, a car wall, a car top and lighting, a ventilation device, a car decoration and a control button board in the car.
  • the equipment car is the part of the car body that is in direct contact with people or goods, and it is particularly important to maintain safe operation.
  • the traction machine is the power equipment of the equipment, also known as the host of the equipment, including the motor, coupling, brake, reducer, machine base, and traction wheel.
  • the traction machine is not well monitored and diagnosed.
  • Machine pumps usually include fans, water pumps, compressors, steam turbines, and other large and small rotating machinery. They are the key production equipment in modern enterprises such as petroleum, chemical, metallurgy, steel, and power.
  • the running condition of the machine pump directly affects the efficiency of the company's production. It can even cause safety problems when the failure is serious.
  • the early signs of the machine pump failure can be found in time to avoid And reduce the occurrence of major production accidents, thereby effectively extending the operating life of the pump, reducing maintenance costs, and achieving safety and efficiency throughout the life cycle of the pump.
  • the technical problem to be solved by the present invention is to overcome the shortcomings in the prior art and provide a vibration temperature sensor for the safe monitoring of the operating data of the operating equipment.
  • the solution of the present invention is:
  • a vibration temperature sensor for the monitoring of the running data of an equipment, including a housing for packaging; a triaxial vibration sensing module, a temperature monitoring module, a filtering module, a data processing module, and a wireless communication module are built in the housing It is connected to the battery module and the three-axis vibration sensing module through the signal line in order to connect the filter module and the data processing module.
  • the temperature monitoring module and the wireless communication module are connected to the data processing module through the signal line.
  • the battery module is used to supply power to each component.
  • a switch module is provided on the casing, and the switch module is connected to the data processing module through a signal line.
  • a magnetic base module is provided at the bottom of the housing, which is used for fixed installation by magnetic attraction.
  • the battery module is a lithium battery with a charging interface.
  • the wireless communication module is a LoRa communication module, a Wi-Fi communication module or an NB-IOT communication module.
  • the calculation software module embedded in the data processing module is used to convert the vibration acceleration data collected by the triaxial vibration sensing module into the effective value of the vibration speed, and output the triaxial vibration through Fourier transform Waveform and spectrogram.
  • the vibration temperature sensor of the present invention has a high degree of integration, is easy to install, and can directly output the temperature value, the effective value of the vibration speed, the triaxial vibration waveform diagram and the frequency spectrum diagram; if the vibration temperature sensor is further used to build the operation/rotation equipment Ankang monitoring system, the whole process is simple and easy to operate.
  • the invention can be used for real-time monitoring of vibration and temperature data during the operation of running equipment, which is convenient for finding early signs of equipment failure in time and avoiding and reducing the occurrence of major accidents. This can effectively extend the operating life of the equipment, reduce maintenance costs, and ensure the safety and efficiency of the equipment throughout its life cycle.
  • the present invention has a built-in wireless communication module, which uses wireless communication to realize the data transmission of the vibration temperature sensor with low cost, high accuracy, and long transmission distance, making Ankang monitoring more convenient and low-cost.
  • FIG. 1 is a schematic diagram of the principle of the vibration temperature sensor in the present invention.
  • Fig. 2 is a schematic diagram of the principle of an Ankang monitoring system using a vibration temperature sensor.
  • the present invention belongs to signal detection technology, and relates to the application of computer technology in the field of industrial production.
  • the application of multiple software function modules will be involved.
  • the applicant believes that, after carefully reading the application documents and accurately understanding the implementation principles and objectives of the present invention, those skilled in the art can fully use the software programming skills they master to implement the present invention in combination with the existing well-known technology.
  • the aforementioned software functional modules include, but are not limited to: computing software modules embedded in data processing modules, operating equipment fault knowledge base, Ankang management and control cloud platform, analysis and diagnosis algorithm software modules, visual output software modules, etc. Are in this category, and applicants will not list them one by one.
  • the vibration temperature sensor of the present invention includes a housing for packaging (such as a 304 stainless steel housing), and a triaxial vibration sensing module, a temperature monitoring module, a filtering module, a data processing module, a wireless communication module, and a battery module are built in the housing.
  • the three-axis vibration sensing module is connected to the filtering module and the data processing module in sequence through the signal line, the temperature monitoring module and the wireless communication module are respectively connected to the data processing module through the signal line, and the battery module is used to supply power to each component.
  • the three-axis vibration sensor module is used to realize the real-time monitoring of the acceleration signals of the three axes (X axis, Y axis, Z axis) of the running equipment.
  • the temperature monitoring module is used to realize real-time monitoring of the surface temperature of the running equipment; the filter module conforms to the ISO10816 vibration level standard, and has anti-aliasing function, which can automatically filter out the low-frequency noise signals below 10Hz in the environment and improve the accuracy of vibration signal monitoring ;
  • the battery module can be selected with a lithium battery with a charging interface, which is used to supply power to various components in the vibration temperature sensor, and the life span is up to 4-5 years;
  • the magnetic base module enables the vibration temperature sensor to be fixed on the running equipment by magnetic attraction (It can also be fixed with glue).
  • a switch module is provided on the casing of the vibration temperature sensor, and the switch module is connected to the data processing module through a signal line.
  • the control object of the switch module can have multiple choices, for example, it can control the switching state of the vibration temperature sensor (power on and off operation), and can also control whether to participate in the network operation of multiple vibration temperature sensors (single machine operation or group Network operation switching operation).
  • the data processing module is a processor chip with computing power, and can select common single chip microcomputer, CPU and so on.
  • the calculation software module is embedded in the data processing module, which is used to convert the vibration acceleration data collected by the triaxial vibration sensing module into the effective value of the vibration speed, and output the triaxial vibration waveform diagram and spectrum diagram through the Fourier transform.
  • the process of data conversion and transformation belongs to the prior art. Among them, for the method of conversion to the effective value of the vibration speed, please refer to the patent document "The Numerical Calculation Method of the Effective Value of the Total Vibration Speed of the Aero Engine” published in June 2013; the conversion output is the triaxial vibration waveform and frequency spectrum For the method, please refer to the paper published in the February 2013 "Partial Vibration of Planetary Gearbox Gears". A person skilled in the art can complete the corresponding calculation according to his mastered skills and actual needs.
  • the wavelet transform is used to preprocess the vibration acceleration data, and then the effective value of the vibration speed is obtained by integral calculation;
  • t is the time of data collection
  • T is the vibration period.
  • the vibration temperature sensor of the present invention is used to monitor the Ankang operation data of the running equipment, but it does not involve the analysis of the Ankang operation state and fault conditions. In order to facilitate the understanding of the present invention, a further application method of the vibration temperature sensor will be described below.
  • Vibration temperature sensor can be used to build an equipment health monitoring system with database server and cloud server to achieve the purpose of equipment health monitoring.
  • Multiple vibration temperature sensors are installed on the running equipment, and data transmission is realized with the database server through wireless communication, and the database server is connected to the cloud server through a cable.
  • the database server is installed in the control center of the equipment room, and has a built-in knowledge base of operating equipment faults; at the same time, it also receives and stores the data collected by the vibration temperature sensor (and video camera) to provide a data basis for fault analysis and diagnosis of operating equipment, and can also be used at any time. Call up historical data for viewing.
  • the wireless communication module can be selected according to the field device installation and database server configuration. Any wireless communication module that can be used for wireless data transmission can be used in the present invention, such as LoRa communication module, Wi-Fi communication module or NB- IOT communication module. According to different choices of wireless communication modules, the corresponding wireless communication transmission mode will also be adjusted accordingly.
  • a LoRa wireless gateway is installed between the vibration temperature sensor and the database server, and the LoRa communication module performs data transmission with the wireless receiving module installed in the database server through the LoRa wireless gateway; (2) The Wi-Fi communication module and The wireless receiving module installed in the database server directly transmits data (within a short distance); or, a Wi-Fi wireless gateway is installed between the vibration temperature sensor and the database server, and the Wi-Fi communication module uses Wi-Fi wireless The gateway performs data transmission (within a longer distance) with the wireless receiving module installed in the database server; (3) The NB-IOT communication module directly transmits data with the wireless receiving module installed in the database server.
  • the LoRa wireless communication method is a low-power, long-distance WAN communication method, with ultra-high data reception sensitivity and super strong signal-to-noise ratio.
  • the Wi-Fi wireless communication method is a close-range, high-precision communication method that can achieve a sampling rate of 128K.
  • the NB-IOT wireless communication method is a low-power long-distance WAN communication method, without the need to deploy a base station, and can achieve long-term data transmission every 20 seconds at the shortest.
  • LoRa wireless gateway and Wi-Fi wireless gateway can further realize data transmission with database server through wireless communication (such as 4G, 5G, etc.).
  • the cloud server is installed in the building's general control room, built-in Ankang management and control cloud platform, and equipped with human-computer interaction equipment; the platform is equipped with the platform with analysis and diagnosis algorithm software module and visual output software module.
  • the analysis and diagnosis algorithm software module performs data perception on a large amount of data collected by the vibration temperature sensor, and analyzes and obtains the effective value of the overall vibration speed of the operating equipment and the operating temperature data. Then compare with the vibration intensity level and operating temperature level of the running equipment stored in the running equipment fault knowledge base to conduct health analysis and safety diagnosis of the equipment. While displaying the results in real time through the visual output software module, real-time warnings or alarms are issued according to preset fault conditions.
  • Based on the Ankang cloud platform for control and wired and wireless (such as 4G, 5G, etc.) communication users of the platform can realize intelligent monitoring and control through mobile terminals such as mobile phones, tablets, and computers, or communicate with platform-based visual software.
  • the operating equipment fault knowledge base is a large knowledge base that can be composed of multiple components.
  • the vibration intensity data and spectrum characteristics of different types of product components of different types of operating equipment under different usage conditions can be aggregated and classified, that is, they can be built into vibration data components of operating equipment components;
  • Standard Such as the ISO2372 vibration standard
  • the overall vibration speed intensity level range to construct the vibration intensity data component
  • (4) history The fault records covered by big data, as well as the integration of mass operating equipment fault examples, constitute a knowledge base component; this component can cover most of the possible operating equipment faults and their detection methods, which are divided into mechanical faults, electrical faults, installation irregularities, There are several major categories such as inadequate maintenance, product component failure, improper use failure and so on.
  • the working status of the running equipment can be monitored 360° in all directions.
  • the video data collected by the video camera is wirelessly transmitted to the database server for storage, and can be called by the Ankang management cloud platform built into the cloud server.
  • the combination of the video data of the camera and the analysis results of the temperature and vibration signal of the vibration temperature sensor can fully guarantee the accuracy and reliability of the diagnostic analysis.
  • the method for applying the vibration temperature sensor of the present invention to the monitoring of the health of running equipment includes the following steps:
  • vibration temperature sensors for the elevator car, there are four vibration temperature sensors, which are respectively installed on the four top corners of the elevator car; for the elevator traction machine, there are three vibration temperature sensors, which are respectively installed in the traction The left end of the base of the machine, the right end of the base of the traction machine, and the bearing end bracket of the traction machine; for the pump, there are two vibration temperature sensors, which are respectively installed on the bearing end and the base end of the pump; As far as the motor is concerned, there are two vibration temperature sensors, which are respectively installed on the casing of the motor main body and the support member of the transmission shaft relative to the distal direction of the motor main body.
  • the data processing module converts the acceleration data into the effective value of the vibration velocity, the vibration waveform diagram and the spectrum diagram ;
  • the wireless communication module transmits the source data and the converted data to the database server for storage through wireless communication transmission;
  • the database of the running equipment fault is built into the database server, and the Ankang cloud platform is built into the cloud server.
  • the platform is equipped with software modules for analysis and diagnosis algorithms and software modules for visual output;
  • the analysis and diagnosis algorithm software module extracts the data stored in the database server and calculates it to obtain the effective value of the overall vibration speed and operating temperature of the operating equipment; after analysis and comparison with the data in the operating equipment fault knowledge base, health analysis and safety are obtained Diagnosis results; while displaying the results in real time through the visual output software module, real-time warnings or alarms are issued according to preset fault conditions.
  • step (2) specifically include:
  • the effective value of the vibration speed obtained by each vibration temperature sensor is weighted according to a predetermined rule to obtain the overall vibration speed of the running equipment; then it is combined with the running equipment vibration in the running equipment fault knowledge base Compare the values corresponding to the intensity level to obtain the health level of the overall vibration speed of the operating equipment;
  • the temperature values obtained by the vibration temperature sensors are weighted according to the predetermined rules to obtain the overall operating temperature value of the operating equipment; then it is combined with the operating temperature of the operating equipment in the knowledge base of the operating equipment fault Compare the values corresponding to the levels to obtain the health level of the overall operating temperature of the operating equipment;
  • the analysis and diagnosis algorithm software module will further analyze the vibration waveform and Extract and analyze the vibration spectrum characteristics of each component of the operating equipment in the spectrum diagram; then compare the analysis results with the spectrum characteristics of each component of different health levels summarized in the operating equipment fault knowledge base, and the visualization output software module displays the comparison results in real time For reference by maintenance personnel.
  • the components for spectrum characteristic comparison refer to the car frame, the car body and the car door;
  • the components for spectrum characteristic comparison refer to the motor , Couplings, brakes, reducers, bases and traction wheels;
  • the components that perform spectral characteristic comparison refer to the base, rotor, sliding bearings, gearbox and impeller;
  • the components that compare the spectral characteristics refer to the magnetic pole, rotor, commutator, brush, housing, bearing and transmission shaft.
  • the vibration intensity can be divided into four different levels of A, B, C, and D; among them, Area A means that the operation is in good condition without any fault problems (health); Area B It indicates that there is a slight vibration during operation, which is the allowable value during operation, and no maintenance is required (healthy, continuous observation is required); Area C indicates that there is obvious vibration during operation. It is recommended to query the cause of the failure through the operation equipment fault knowledge base. (Sub-health, it is recommended to carry out corresponding maintenance); Area D indicates that there is severe vibration during operation, and the operation of the equipment must be stopped immediately for emergency maintenance (failure, analysis of the vibration spectrum characteristics of related components is required).
  • the operating temperature can be divided into four different grade ranges of A, B, C, and D; among them, area A indicates that the operating condition is good and there is no failure problem (health); area B indicates There is a slight temperature rise during operation, which is the allowable value during operation and does not require maintenance (healthy, continuous observation is required); Area C indicates that there is a significant temperature increase during operation. It is recommended to query the cause of the failure through the operating equipment failure knowledge base Analysis (sub-health, it is recommended to carry out corresponding maintenance); Area D indicates that there is a rapid temperature rise during operation, and the equipment must be stopped immediately for emergency maintenance (failure, analysis of the vibration spectrum characteristics of related components is required).
  • each component of the running equipment Due to the difference in materials and shapes, each component of the running equipment has a different range of fixed vibration spectrum characteristics. Different operating states will show different vibration spectrum characteristics in the vibration waveform diagram and spectrum diagram; The vibration spectrum characteristics of the healthy operating equipment are detected under normal operation, and the massive fault spectrum characteristics of the operating equipment tracked by field applications such as literature and projects are collected to form a database component of the knowledge base. By comparing and analyzing the vibration spectrum characteristics obtained from the analysis with the knowledge base, the failure type and failure level of each component of the running equipment can be obtained.
  • Local maintenance personnel who install and operate equipment can connect to cloud servers through mobile terminals such as mobile phones, tablets, and laptops. From the Ankang cloud control platform, they can keep abreast of equipment operation or fault conditions in order to carry out targeted maintenance or maintenance, and can The earth improves work efficiency.
  • the vibration temperature sensor of the present invention can be applied not only to the operation equipment (such as elevator car, elevator traction machine, machine pump, motor) that have been exemplified, but also to almost all types of Run the device and rotate the device. Any application or modification made by those skilled in the art without departing from the spirit and scope of the present invention shall fall within the protection scope of the present invention.

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  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
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  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
  • Measurement Of Mechanical Vibrations Or Ultrasonic Waves (AREA)

Abstract

一种用于运转设备运行数据安康监测的振动温度传感器，包括用于封装的外壳；在外壳中内置了三轴向振动传感模块、温度监测模块、滤波模块、数据处理模块、无线通讯模块和电池模块，三轴向振动传感模块通过信号线依次连接滤波模块和数据处理模块，温度监测模块和无线通讯模块分别通过信号线连接数据处理模块，电池模块用于为各元器件供电。该振动传感器集成程度高、安装方便；能够直接输出振动速度有效值、三轴向振动波形图和频谱图。如果进一步利用该振动温度传感器搭建运行/转动设备的安康监测系统，整个过程简单易操作。

Description

一种用于运转设备运行数据安康监测的振动温度传感器 技术领域
本发明属于智能控制领域，具体涉及一种用于运转设备运行数据安康监测的振动温度传感器，主要用于运转设备的运行数据监测。
背景技术
运转设备包括运行设备和转动设备，广泛应用于日常生产生活之中。
例如，设备轿厢的轿厢架是轿厢体的承重构架，由横梁、立柱、底梁和斜拉杆等组成。轿厢体由轿厢底、轿厢壁、轿厢顶及照明、通风装置、轿厢装饰件和轿内操纵按钮板等组成。设备轿厢是直接与人员或货物直接接触的轿体部分，保持安全运行尤为重要。
设备的运行过程中主要靠曳引机输送与传递动力并驱动，曳引机是设备的动力设备，又称设备主机，包括电动机、联轴器、制动器、减速器、机座、曳引轮这几个主要部件。设备事故频发，大多数是因为曳引机各部件出现问题不能正常工作，没有做到对曳引机进行很好的监测和诊断分析。
机泵通常包括风机、水泵、压缩机、汽轮机等大小型旋转机械，是石油、化工、冶金、钢铁和电力等现代企业中的关键生产设备。机泵的运行状况好坏直接影响着企业生产的效率，发生故障严重时甚至会造成安全问题，通过对机泵的实时监测和故障的诊断分析，能及时发现机泵故障的早期征兆，能够避免和减少重大生产事故的发生，从而有效延长机泵运行寿命，降低维修费用，实现机泵全生命周期的安全与高效。
石油、化工、汽车等各行各业都大量应用电机作为原动机去拖动各种生产机械。然而电机振动有如下危害：消耗能量，使电动机的效率降低；直接伤害电机轴承，加速电机轴承的磨损，使轴承的正常寿命大大缩短；使转子磁极松动，造成定子和转子相互擦碰，从而导致电机转子弯曲、断裂；使电机端部绑线松动，造成端部绕组相互摩擦，绝缘电阻降低，绝缘寿命缩短，严重时造成绝缘击穿；使基础或与电机配套的其他设备的运转受到影响，造成某些零件松动，甚至使一些零件因疲劳而损伤，造成事故。
目前，尚无能够简单实用的用于运转设备运行数据监测的振动温度传感器。
发明内容
本发明要解决的技术问题是，克服现有技术中的不足，提供一种用于运转设备运行数据安康监测的振动温度传感器。
为解决技术问题，本发明的解决方案是：
提供一种用于运转设备运行数据安康监测的振动温度传感器，包括用于封装的外壳；在外壳中内置了三轴向振动传感模块、温度监测模块、滤波模块、数据处理模块、无线通讯模块和电池模块，三轴向振动传感模块通过信号线依次连接滤波模块和数据处理模块，温度监测模块和无线通讯模块分别通过信号线连接数据处理模块，电池模块用于为各元器件供电。
本发明中，在外壳上设置开关模块，开关模块通过信号线连接数据处理模块。
本发明中，在外壳底部设有磁座模块，用于以磁吸方式进行固定安装。
本发明中，所述电池模块是带有充电接口的锂电池。
本发明中，所述无线通讯模块是LoRa通讯模块、Wi-Fi通讯模块或NB-IOT通讯模块。
本发明中，所述数据处理模块中内嵌计算软件模块，用于将三轴向振动传感模块采集的振动加速度数据转换为振动速度有效值，以及通过傅里叶变换输出为三轴向振动波形图和频谱图。
与现有技术相比，本发明的有益效果是：
1、本发明的振动温度传感器具有集成程度高、安装方便，能够直接输出温度值、振动速度有效值、三轴向振动波形图和频谱图；如果进一步利用该振动温度传感器搭建运行/转动设备的安康监测系统，整个过程简单易操作。
2、本发明能够用于对运转设备运行过程中振动、温度数据进行实时监测，便于及时发现设备故障的早期征兆，避免和减少重大事故的发生。从而能有效延长设备运行寿命，降低维修费用，保证设备全生命周期的安全、高效。
3、本发明内置无线通讯模块，采用无线通讯方式实现振动温度传感器的数据传送的成本低、精确度高、传输距离远，使得安康监测更加方便和低成本。
附图说明
图1为本发明中振动温度传感器的原理示意图。
图2为使用振动温度传感器的安康监测系统的原理示意图。
具体实施方式
为了使本发明的目的和技术方案以及优点更加清楚明白，结合附图作进一步详细说明。应当理解，此处所描述的具体实施例仅拥有解释本发明，并不用与限定本发明。
首先需要说明的是，本发明属于信号检测技术，涉及计算机技术在工业生产领域的应用。在本发明所介绍的具体实现或应用过程中，将会涉及到多个软件功能模块的应用。申请人认为，如在仔细阅读申请文件、准确理解本发明的实现原理和发明目的以后，在结合现有公知技术的情况下，本领域技术人员完全可以运用其掌握的软件编程技能实现本发明。前述软件功能模块包括但不限于：内嵌于数据处理模块的计算软件模块、运转设备故障知识库、安康管控云平台、分析诊断算法软件模块、可视化输出软件模块等，凡本发明申请文件提及的均属此范畴，申请人不再一一列举。
本发明所述振动温度传感器包括用于封装的外壳(如304不锈钢外壳)，外壳中内置了三轴向振动传感模块、温度监测模块、滤波模块、数据处理模块、无线通讯模块和电池模块，三轴向振动传感模块通过信号线依次连接滤波模块和数据处理模块，温度监测模块和无线通讯模块分别通过信号线连接数据处理模块，电池模块用于为各元器件供电。
在振动温度传感器中，三轴向振动传感模块用于实现运转设备三轴向(X轴、Y轴、Z轴)加速度信号的实时监测，可选用美国TE Connectivity生产的MEAS 7131A-0050三轴振动加速度芯片。温度监测模块用于实现运转设备表面温度实时监测；滤波模块符合ISO 10816振动量级标准，具备抗混叠的功能，可自动过滤掉环境中10Hz以下的低频噪音信号，提高振动信号监测的精确性；电池模块可选带有充电接口的锂电池，用于为振动温度传感器中各元器件供电，寿命长达4-5年；磁座模块使振动温度传感器能以磁吸方式固定在运转设备上(也可以用胶粘方式固定)。在振动温度传感器的外壳上设置开关模块，开关模块通过信号线连接数据处理模块。开关模块的控制对象可以有多种选择，例如可以对振动温度传感器的开关状态进行控制(通断电操作)，也可以对是否参与多个振动温度传感器共同组网运行进行控制(单机运行或组网运行切换操作)。
数据处理模块是具备运算能力的处理器芯片，可选常见的单片机、CPU等。数据处理模块中内嵌计算软件模块，用于将三轴向振动传感模块采集的振动加速度数据转换为振动速度有效值，以及通过傅里叶变换输出为三轴向振动波形图和频谱图，该数据转换和变换过程均属于现有技术。其中，转换为振动速度有效值的方法，可参考2013年6月公开的《航空发动机整机振动总量速度有效值数值计算方法》专利文献；变换输出为三轴向振动波形图和频谱图的方法，可参考2013年2月公开的《行星齿轮箱齿轮局部 故障振动》论文文献。本领域技术人员可根据其掌握的技能并结合实际需要完成相应计算。
下面举例说明将振动加速度数值转换为振动速度有效值的过程：
首先通过小波变换对振动加速度进行数据预处理，然后通过积分计算得到振动速度有效值；
对振动加速度信号a(t)进行积分运算得到振动速度值v(t)，如公式(1)：
Figure PCTCN2019122515-appb-000001
其中，t为数据采集的时间；
再根据振动速度值v(t)求得振动速度有效值vrms，如公式(2)：
Figure PCTCN2019122515-appb-000002
其中，T为振动周期。
本发明所述振动温度传感器用于监测运转设备的安康运行数据，但并不涉及对其安康运行状态和故障情况的分析。为便于理解本发明，下面对振动温度传感器的进一步应用方法进行描述。
振动温度传感器可用于与数据库服务器和云服务器搭建运转设备安康监测系统，以便实现运转设备安康监测的目的。是将多个振动温度传感器安装在运转设备上，并通过无线通讯方式与数据库服务器实现数据传输，数据库服务器通过线缆连接云服务器。
数据库服务器安装在设备机房控制中心，内置运转设备故障知识库；同时也接收由振动温度传感器(以及视频摄像头)采集的数据并进行存储，为运转设备的故障分析和诊断提供数据基础，也可随时调出历史数据供查看。
本发明中，无线通讯模块可根据现场设备安装和数据库服务器配置的情况进行选择，凡可用于无线数据传送的无线通讯模块均可用于本发明，例如LoRa通讯模块、Wi-Fi通讯模块或NB-IOT通讯模块。根据无线通讯模块的不同选择，相应的无线通信传输方式也会进行相应调整。例如：(1)在振动温度传感器与数据库服务器之间设置LoRa无线网关，LoRa通讯模块通过LoRa无线网关与设于在数据库服务器中的无线接收模块进行数据传输；(2)Wi-Fi通讯模块与设于在数据库服务器中的无线接收模块直接进行(短距离范围内的)数据传输；或者，在振动温度传感器与数据库服务器之间设置Wi-Fi无线网关，Wi-Fi通讯模块通过Wi-Fi无线网关与设于在数据库服务器中的无线接收模 块进行(较长距离范围内的)数据传输；(3)NB-IOT通讯模块与设于在数据库服务器中的无线接收模块直接进行数据传输。
LoRa无线通讯方式是一种低功耗、长距离的广域网通讯方式，拥有超高的数据接收灵敏度和超强的信噪比。Wi-Fi无线通讯方式是一种近距离、高精度的通讯方式，可实现128K的采样率。NB-IOT无线通讯方式是一种低功耗长距离的广域网通讯方式，无须部署基站，可实现最短每隔20秒长传一次数据。LoRa无线网关和Wi-Fi无线网关可进一步通过无线通信方式(如4G、5G等)实现与数据库服务器之间的数据传输。
云服务器安装在建筑总控制室，内置安康管控云平台，并配置人机交互设备；该平台具备该平台具备分析诊断算法软件模块和可视化输出软件模块。分析诊断算法软件模块通过对振动温度传感器采集的大量数据进行数据感知，分析获得运转设备的整体振动速度有效值和运行温度数据。再与运转设备故障知识库中存储的运转设备振动烈度等级和运行温度等级进行对比，对设备进行健康分析和安全诊断。在通过可视化输出软件模块实时显示结果的同时，根据预设故障条件发出实时预警或报警。基于安康管控云平台以及有线、无线(如4G、5G等)方式通讯，平台的用户可通过手机、平板、电脑等操作终端实现智能化监测与管控，或者基于平台的可视化软件进行通信。
运转设备故障知识库是一个大型知识库，可以由多个组件构成。例如：(1)将各品类运转设备不同型号的产品部件在不同使用状态下的振动烈度数据和频谱特征进行汇总、归类，即能构建成为运转设备部件振动数据组件；(2)以标准(如ISO2372振动标准)规定的整体振动速度烈度等级范围构建振动烈度数据组件；(3)以标准(如JB/T5294-91温度标准)规定的运行温度等级范围构建温度数据组件；(4)以历史大数据覆盖的故障记录，以及整合海量运转设备故障实例组成知识库组件；该组件能够涵盖大部分运转设备可能出现的故障及其检测方法，分为机械类故障、电气类故障、安装不规范、保养不到位、产品元件故障、使用不当故障等几大类。
通过在运转设备上(例如在轿厢内顶部中央)安装视频摄像头，可全方位360°监视运转设备的工作状态。视频摄像头采集的视频数据经无线方式传送给数据库服务器存储，并能由云服务器中内置的安康管控云平台调用。摄像头的视频数据与振动温度传感器的温度、振动信号的分析结果相结合，能充分保障诊断分析的准确性和可靠性。
将本发明所述振动温度传感器应用于运转设备安康监测的方法，包括以下步骤：
(1)在运转设备上设置多个振动温度传感器；
例如：对于电梯轿厢而言，振动温度传感器一共有4个，分别安装电梯轿厢的4个顶角上；对于电梯曳引机而言，振动温度传感器一共有3个，分别安装在曳引机的基座左端、曳引机基座右端，以及曳引机轴承端支架上；对于机泵而言，振动温度传感器一共有2个，分别安装在机泵的轴承端和基座端；对于电机而言，振动温度传感器一共有2个，分别安装在电机主机的外壳上，以及传动轴相对于电机主机远端方向的支承部件上。
利用内置于振动温度传感器的三轴向振动传感模块获取振动加速度信号和温度信号；经滤波模块消除杂波后，由数据处理模块将加速度数据转换为振动速度有效值、振动波形图和频谱图；无线通讯模块通过无线通信传输方式，将源数据和转换后的数据传送至数据库服务器进行存储；
(2)数据库服务器中内置运转设备故障知识库，云服务器中内置安康管控云平台，该平台具备分析诊断算法软件模块和可视化输出软件模块；
分析诊断算法软件模块提取数据库服务器中存储的数据并进行计算，获得运转设备的整体振动速度有效值和运行温度；在与运转设备故障知识库中的数据进行分析与对比后，获得健康分析和安全诊断结果；在通过可视化输出软件模块实时显示结果的同时，根据预设故障条件发出实时预警或报警。
步骤(2)中所述的分析与比对具体包括：
(2.1)针对运转设备整体振动速度的分析与比对
分析诊断算法软件模块提取数据后，根据预定规则对各振动温度传感器获取的振动速度有效值进行加权计算，获得运转设备整体振动速度；然后将其与汇总于运转设备故障知识库中的运转设备振动烈度等级对应的数值进行比较，获得运转设备整体振动速度的健康等级；
(2.2)针对运转设备运行温度的分析与比对
分析诊断算法软件模块提取数据后，根据预定规则对各振动温度传感器获取的温度值进行加权计算，获得运转设备整体运行温度数值；然后将其与汇总于运转设备故障知识库中的运转设备运行温度等级对应的数值进行比较，获得运转设备整体运行温度的健康等级；
(2.3)针对运转设备各部件振动频谱特征的分析与比对
在步骤(2.1)或(2.2)获得的诊断结果中，只要运转设备整体振动速度或运行温度中任意一项的健康等级属于应停机维修的，就进一步由分析诊断算法软件模块从振动波形图和频谱图中提取和分析运转设备各部件的振动频谱特征；然后将分析结果与汇总 于运转设备故障知识库中不同健康等级的各部件频谱特征进行比对，由可视化输出软件模块实时显示比对结果，以供维修人员参考。
其中：对于电梯轿厢而言，进行频谱特征比对的各部件是指轿厢架、轿厢体和轿厢门；对于电梯曳引机而言，进行频谱特征比对的各部件是指电动机、联轴器、制动器、减速器、机座和曳引轮；对于机泵而言，进行频谱特征比对的各部件是指基座、转子、滑动轴承、齿轮箱和叶轮；对于电机而言，进行频谱特征比对的各部件是指磁极、转子、换向器、电刷、机壳、轴承和传动轴。
运转设备安康监测方法的应用示例：
1、根据运转设备整体振动速度的不同，可以将振动烈度分为A、B、C、D四个不同的等级范围；其中，A区表示运行状况良好，无任何故障问题(健康)；B区表示运行中有略微振动，是运行过程中的允许值，不需要进行维修(健康，需持续观察)；C区表示运行中有明显的振动，建议通过运转设备故障知识库进行查询故障原因的分析(亚健康，建议进行对应的维修保养)；D区表示运行中有剧烈的振动，须立即停止设备运行进行紧急维修(故障，需进行相关部件振动频谱特征的分析)。
2、根据运转设备运行温度的不同，可以将运行温度分为A、B、C、D四个不同的等级范围；其中，A区表示运行状况良好，无任何故障问题(健康)；B区表示运行中有略微温升，是运行过程中的允许值，不需要进行维修(健康，需持续观察)；C区表示运行中有明显的温度升高，建议通过运转设备故障知识库进行查询故障原因的分析(亚健康，建议进行对应的维修保养)；D区表示运行中有急速的升温现象，须立即停止设备运行进行紧急维修(故障，需进行相关部件振动频谱特征的分析)。
3、针对运转设备各部件振动频谱特征的分析与比对
组成运转设备的各部件因其材质和形状的差异性，有着相互区别的固定振动频谱特征范围，不同的运行状态会在振动波形图和频谱图中表现为不同的振动频谱特征；通过对刚出厂的健康运转设备的正常运行状态下振动频谱特征进行检测，以及利用文献、项目等现场应用跟踪到的运转设备海量的故障频谱特征收集以形成知识库的数据库组件。在将分析所得振动频谱特征与知识库进行对比、分析，即能获得运转设备的各部件的故障类型和故障等级。
在安装运转设备本地的维保人员可通过手机、平板、笔记本电脑等操作终端连接至云服务器，从安康管控云平台及时了解设备运行或故障情况，以便有针对性地进行保养或维护，能够极大地提高工作效率。
虽然本发明已以较佳实施例披露如上，但本发明并非限定于此。例如，本发明所述振动温度传感器不仅仅能够应用在不仅仅局限于已举例的运转设备(如电梯轿厢、电梯曳引机、机泵、电机)，还可应用到几乎全部各类形式的运行设备和转动设备上。任何本领域技术人员，在不脱离本发明的精神和范围内所做出的应用或改动，均应属于本发明的保护范围。

Claims (6)

  1. 一种用于运转设备运行数据安康监测的振动温度传感器，包括用于封装的外壳；其特征在于，在外壳中内置了三轴向振动传感模块、温度监测模块、滤波模块、数据处理模块、无线通讯模块和电池模块，三轴向振动传感模块通过信号线依次连接滤波模块和数据处理模块，温度监测模块和无线通讯模块分别通过信号线连接数据处理模块，电池模块用于为各元器件供电。
  2. 根据权利要求1所述的振动温度传感器，其特征在于，在外壳上设置开关模块，开关模块通过信号线连接数据处理模块。
  3. 根据权利要求1所述的振动温度传感器，其特征在于，在外壳底部设有磁座模块，用于以磁吸方式进行固定安装。
  4. 根据权利要求1所述的振动温度传感器，其特征在于，所述电池模块是带有充电接口的锂电池。
  5. 根据权利要求1所述的振动温度传感器，其特征在于，所述无线通讯模块是LoRa通讯模块、Wi-Fi通讯模块或NB-IOT通讯模块。
  6. 根据权利要求1至5任意一项中所述的振动温度传感器，其特征在于，所述数据处理模块中内嵌计算软件模块，用于将三轴向振动传感模块采集的振动加速度数据转换为振动速度有效值，以及通过傅里叶变换输出为三轴向振动波形图和频谱图。
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