混凝土砌块成型生产线远程监控与诊断系统的研究
|
摘要
制造装备远程监控与故障诊断技术在保证设备安全、稳定、长周期优质运行方面发挥了很大的作用。本文以QT10-15混凝土砌块成型生产线为对象,着重研究了该混凝土砌块成型生产线远程监控、诊断的关键技术和系统实现方案。
论文在分析基于PLC平台的系统构成及实现方法的基础上,详细研究了台达EH型PLC的串口通讯机制,借助VB6.0的通信控件,实现了混凝土砌块成型生产线现场PC对PLC的信号采集功能;研究设计了基于嵌入式工控主板+DSP结构的嵌入式智能监控与维护单元,实现了对混凝土砌块成型生产线现场视声信号、模拟量信号的采集与传输,为系统监控信息多元化提供了技术基础。基于C/S结构,组建生产线现场PC与监控中心服务器的网络连接,并利用Sock机制,配合自定义的现场信号网络传输协议,实现基于以太网的生产线现场PC和监控中心之间数据传输;研究GSM模块通讯技术,实现了混凝土砌块成型生产线故障信息向监控中心的短消息传输,以此作为对有线传输的强力补充。最后,分析生产线故障特征,应用Access和ADO技术,开发混凝土砌块成型生产线的故障诊断数据库,实现对生产线故障诊断、历史数据汇总与分析,并为用户提供生产线维护与改进意见。
现场调试和运行表明:本文设计的QT10-15混凝土砌块成型生产线远程监控与诊断系统达到了预期的功能要求,具有较好的可靠性和实用性,满足生产线的监控要求。
The remote monitoring and fault diagnosis technologies have played a significant role in ensuring the security, stability and long-term high-quality operation of manufacturing equipment. In this dissertation, a research has been focused on the key technologies of remote monitoring and diagnosis and systemic realizable programme of QT10-15 concrete block molding production line.
Based on the analysis of the system composing and implement method of PLC based system, a detailed research has been made on the serial communication mechanism of Delta EH-PLC in this dissertation. Based on the communications control of VB6.0, the PLC signal acquisition function of concrete block molding production line host is achieved. To make the monitoring signals diversified, an embedded computer motherboards + DSP embedded intelligent monitoring and maintenance unit is designed. This unit is the right equipment of the scene and audio information, as production, acquitting some analog signals and transmitting in a long distance. Based on C/S structure, the network connection between the concrete block molding production line host and the monitoring center server has been set up. Using the Sock mechanism and custom signal transmission protocol, the Ethernet-based data transmission between the concrete block molding production line host and monitoring center server is achieved. Researching the GSM communication technology, the abnormal of concrete block molding production line will be sent to the remote monitoring server in the form of short message. This is a powerful added to the cable transmission. Finally, analyzing the fault features, the fault diagnosis database of concrete block molding production line is designed with the access and ADO technology. The summary and analysis of historical data can be achieved. The data can provide the views of maintenance and improvement.
It is proved by field experiment and operation that the designed remote monitoring system of the concrete block molding production line reaches the expected function demand. The design which is dependable and practicable satisfies the requirements of monitoring of production line.
论文在分析基于PLC平台的系统构成及实现方法的基础上,详细研究了台达EH型PLC的串口通讯机制,借助VB6.0的通信控件,实现了混凝土砌块成型生产线现场PC对PLC的信号采集功能;研究设计了基于嵌入式工控主板+DSP结构的嵌入式智能监控与维护单元,实现了对混凝土砌块成型生产线现场视声信号、模拟量信号的采集与传输,为系统监控信息多元化提供了技术基础。基于C/S结构,组建生产线现场PC与监控中心服务器的网络连接,并利用Sock机制,配合自定义的现场信号网络传输协议,实现基于以太网的生产线现场PC和监控中心之间数据传输;研究GSM模块通讯技术,实现了混凝土砌块成型生产线故障信息向监控中心的短消息传输,以此作为对有线传输的强力补充。最后,分析生产线故障特征,应用Access和ADO技术,开发混凝土砌块成型生产线的故障诊断数据库,实现对生产线故障诊断、历史数据汇总与分析,并为用户提供生产线维护与改进意见。
现场调试和运行表明:本文设计的QT10-15混凝土砌块成型生产线远程监控与诊断系统达到了预期的功能要求,具有较好的可靠性和实用性,满足生产线的监控要求。
The remote monitoring and fault diagnosis technologies have played a significant role in ensuring the security, stability and long-term high-quality operation of manufacturing equipment. In this dissertation, a research has been focused on the key technologies of remote monitoring and diagnosis and systemic realizable programme of QT10-15 concrete block molding production line.
Based on the analysis of the system composing and implement method of PLC based system, a detailed research has been made on the serial communication mechanism of Delta EH-PLC in this dissertation. Based on the communications control of VB6.0, the PLC signal acquisition function of concrete block molding production line host is achieved. To make the monitoring signals diversified, an embedded computer motherboards + DSP embedded intelligent monitoring and maintenance unit is designed. This unit is the right equipment of the scene and audio information, as production, acquitting some analog signals and transmitting in a long distance. Based on C/S structure, the network connection between the concrete block molding production line host and the monitoring center server has been set up. Using the Sock mechanism and custom signal transmission protocol, the Ethernet-based data transmission between the concrete block molding production line host and monitoring center server is achieved. Researching the GSM communication technology, the abnormal of concrete block molding production line will be sent to the remote monitoring server in the form of short message. This is a powerful added to the cable transmission. Finally, analyzing the fault features, the fault diagnosis database of concrete block molding production line is designed with the access and ADO technology. The summary and analysis of historical data can be achieved. The data can provide the views of maintenance and improvement.
It is proved by field experiment and operation that the designed remote monitoring system of the concrete block molding production line reaches the expected function demand. The design which is dependable and practicable satisfies the requirements of monitoring of production line.
引文
[1]Lee J.制造全球化的挑战及研究战略.中国机械工程,1997(8):27-28
[2]Lee J.Tele-service engineering in manufacturing:challenges and oppommities Intemet.Machine Tools and Manufacture,1998(6):901-910
[3]孙宇,张世琪.柔性制造监测监控技术.第1版.北京:兵器工业出版社,2002
[4]陶波.基于嵌入式Intemet的工业控制.测控技术,2001(8):5-7
[5]王坚,张浩,严隽薇,吴启迪.基于Intemet/Intranet的数字化远程故障诊断系统.计算机工程,2000,26(10):28-29
[6]樊留群,朱志浩,张浩,吴启迪.建立远程服务系统的研究.同济大学学报,1999,27(4):482-486
[7]Somnath D,Krishna A,Pattipati R,Roshan.SQSI's Integrated Diagnostics Toolset.IEEE AUTOTESTCON,1997:P408-P421
[8]孙宇,张世琪,张建民,路宝春.柔性制造检测监控技术.第1版.北京:兵器工业出版社,2000
[9]Chinmaya Kar,A.R.Mohanty.Vibration and current transient monitoring for gearbox fault detection using multiresolution Fourier transform.Journal of Sound and Vibration,2008,311(4):109-132
[10]袁小宏,李辛毅,屈梁生.基于因特网的设备远程诊断中心设计.中国机械工程,2002,13(10):874-876
[11]李黎辉,刘会霞,王霄,谢赞.基于Web的开放式数控机床网络化远程监控系统开发.制造技术与机床,2008(3):9-12
[12]梁列全.工程机械远程监控系统应用研究.矿用汽车,2007(4):20-25
[13]Ong S,An N,Nee N.Web-Based Fault Diagnostic and Learning System.The International Journal of Advanced Manufacturing Technology,2001,18(7):502-511
[14]陆宝春,张卫,徐永新.支持敏捷制造的控制系统体系结构研究.中国制造业信息化,2003,32(11):80-82,86
[15]李光宇,李延新,袁爱进.基于C/S模型的OPC客户端实现远程监控.微计算机信息,2007,4(14):25-26
[16]朱军,金志刚.三层网络体系结构的特点和实现方法.电子工程师,2003,29(3):10-13
[17]Cen Nan,Faisal Khan.Real-time fault diagnosis using knowledge-based expert system.Process Safety and Environmental Protection,2008,86(11):55-71
[18]高明.故障诊断技术在矿山设备机械维修中的应用.内蒙古科技与经济,2006(12):164-166
[19]刘翠玲,黄建兵.集散控制系统.第1版.北京:北京大学版社,2006
[20]王贵成,宋琳,徐心和.一种基于PLC的远程监控系统的设计.微计算机信息,2005,21(7):116-118
[21]Boris V,Proto P,Anthony S.A Multithreaded Message Passing Interface(MPI)Architecture:Performance and Program Issues.Journal of Parallel and Distributed Computing,2001,4(26):61-69
[22]余华.基于PC-PLC的电梯远程监控系统的设计与实现.自动化与仪器仪表,2005(3):12-14
[23]Mano Ram Maurya,Raghunathan Rengaswamy.Fault diagnosis using dynamic trend analysis:A review and recent developments.Engineering Applications of Artificial Intelligence,2007,20(3):133-146
[24]莫兆祥,楚伟华.闸门自动化远程监控方式设计与分析.机电一体化,2008(1):89-92
[25]陆宝春,田先春,平晓锋,陈冬冬.混凝土砌块成型生产线的嵌入式智能监控与维护单元设计.中国制造业信息化,2007,19(36):58-62
[26]杨健,张慧慧.一种支持网络协议的嵌入式敏捷化智能维护单元的实现.高技术通讯,2006,16(2):67-71
[27]陆宝春,雷学东,周静.制造系统的智能监控和诊断.南京理工大学学报,2005,29(3):112-116
[28]谢志江,郭煜敬.分布式远程故障诊断平台研究.现代制造工程,2007(7):103-104,121
[29]Kajetanowicz M,Samek M,Sierpowski D,Stoehlker Th.Digital processing of Ge-detector signals.Radiation Physics and Chemistry,2006,75(9):1972-1976
[30]Jameel A,Siyal M,Ahmed N.Transform-domain and DSP based secure speech communication system.Microprocessors and Microsystems,2007,31:335-346
[31]向移山.基于MPEG-4的视频数字水印技术研究.燕山大学学报,2006,01:57-61
[32]周利,余愚.机械故障诊断中人工智能的应用.可编程控制器与工厂自动化(PLC FA),2007(7):36-38,40
[33]Joe A,Tseng C.A GSM-based remote wireless automatic monitoring system for field information:A case study for ecological monitoring of the oriental fruit fly, Bactrocera dorsalis.Computers and Electronics in Agriculture,2008,1(3):243-259
[34]Ming-Chung Tang.Exploiting GSM short message service for ubiquitous accessing.Journal of Network and Computer Applications,2001,24(3):247-267
[35]Jaewon Kang,Badri Nath.A study on switching voice traffic seamlessly between GSM and GPRS cellular networks.Computer Communications,2006,29(6):1079-1093
[36]Goma J,Mario Z.GSM wireless solutions in distributed embedded systems designed for automatic control.ELMAR,2004,6(22):14-16
[37]别丽华,蒋天发.柔性制造监测监控技术.武汉理工大学学报,2002,30(3):474-477
[38]Siemens A G.TC35/TC37 Siemens Cellular Engines Hardware Interface Description.Siemens AG,2002
[39]Pravin P,Bert-Jan van Beijnum,Marten van Sinderen.Performance Evaluation of the Context-Aware Handover Mechanism for the Nomadic Mobile Services in Remote Patient Monitoring.Computers and Electronics in Agriculture,2008,7(10):243-259
[40]宋超,李欣,董静薇.基于TC35i的无线数据采集系统.哈尔滨理工大学学报,2007,12(2):103-106
[41]李鸣,魏震生.武器装备远程分布式测试与诊断系统的研究及实现.测控技术,2006,25(12):10-13
[42]席晨飞,蔡慧林.基于GSM短消息与PLC的远程气象监测系统.自动化技术与应用,2007,26(11):43-45
[43]马潮.嵌入式GSM短消息接口的软硬件设计.单片机与嵌入式系统应用,2002(7):25-28
[44]魏英钦,陈连坤.基于TC35i的PC机短消息收发模块.电子世界,2007(2):22-24
[45]郭瑞军,谢晗昕,唐邦民.Visual Basic数据库开发实例精粹.第2版.北京:兵器工业出版社,2007
[46]张松林.机械产品两种模块化设计方法.交通与计算机.2001.19(3):621-64
[47]Tiit Kutser,Liisa Metsamaa.Influence of the vertical distribution of bacteria in the water column on the remote sensing signal.Estuarine Coastal and Shelf Science,2007,24(13):1016-1021
[48]Black U D.TCP/IP and Related Protocols.McGraw-Hill,1995,1:1-4
[49]任强,张华伟.WinSock网络编程技术在数控系统远程监控中的应用.机电工程技术,2007,36(8):69-71
[50]李春葆,刘圣才,张植民.Visual Basic程序设计.第1版.北京:清华大学出版社,2005
[51]Guan J,Braham J H.An integrated approach for fault diagnosis with learning.Computers in Industry,1996(32):33-51
[52]吴今培,肖健华.智能故障诊断与专家系统.第2版.北京:科学出版社,1997
[53]Marko Knezevic,Surya R.Kalidindi,David Fullwood.Computationally efficient database and spectral interpolation for fully plastic Taylor-type crystal plasticity calculations of face-centered cubic polycrystals.International Journal of Plasticity,2008,24(2):1264-1276
[54]Mahesh Kumar Jar,Garg P K.Monitoring and modelling of urban sprawl using remote sensing and GIS techniques.International Journal of Applied Earth Observation and Geoinformation,2008,10(7):26-43
[55]Q Gao,C Duan,H Fan.Rotating machine fault diagnosis using empirical mode decomposition.Mechanical Systems and Signal Processing,2008,22(9):1072-1081
[56]姚巍.Visual Basic数据库开发及工程实例.第1版.北京:人民邮电出版社,2003
[57]朱大奇,刘永安.故障诊断的信息融合方法.控制与决策,2007,22(12):1321-1328
[58]梁涛,马爱龙.具有远程监控功能的换热站自动控制系统.电子应用技术,2007,33(10):93-96
[59]李芳,贺雨田.基于VB的液压在线监测与故障诊断仪的上位机软件设计.石油仪器,2008,22(1):90-92
[60]陆明春,张学启.一种大型旋转机械远程在线监测和故障诊断系统.天津冶金,2008(1):55-57
[2]Lee J.Tele-service engineering in manufacturing:challenges and oppommities Intemet.Machine Tools and Manufacture,1998(6):901-910
[3]孙宇,张世琪.柔性制造监测监控技术.第1版.北京:兵器工业出版社,2002
[4]陶波.基于嵌入式Intemet的工业控制.测控技术,2001(8):5-7
[5]王坚,张浩,严隽薇,吴启迪.基于Intemet/Intranet的数字化远程故障诊断系统.计算机工程,2000,26(10):28-29
[6]樊留群,朱志浩,张浩,吴启迪.建立远程服务系统的研究.同济大学学报,1999,27(4):482-486
[7]Somnath D,Krishna A,Pattipati R,Roshan.SQSI's Integrated Diagnostics Toolset.IEEE AUTOTESTCON,1997:P408-P421
[8]孙宇,张世琪,张建民,路宝春.柔性制造检测监控技术.第1版.北京:兵器工业出版社,2000
[9]Chinmaya Kar,A.R.Mohanty.Vibration and current transient monitoring for gearbox fault detection using multiresolution Fourier transform.Journal of Sound and Vibration,2008,311(4):109-132
[10]袁小宏,李辛毅,屈梁生.基于因特网的设备远程诊断中心设计.中国机械工程,2002,13(10):874-876
[11]李黎辉,刘会霞,王霄,谢赞.基于Web的开放式数控机床网络化远程监控系统开发.制造技术与机床,2008(3):9-12
[12]梁列全.工程机械远程监控系统应用研究.矿用汽车,2007(4):20-25
[13]Ong S,An N,Nee N.Web-Based Fault Diagnostic and Learning System.The International Journal of Advanced Manufacturing Technology,2001,18(7):502-511
[14]陆宝春,张卫,徐永新.支持敏捷制造的控制系统体系结构研究.中国制造业信息化,2003,32(11):80-82,86
[15]李光宇,李延新,袁爱进.基于C/S模型的OPC客户端实现远程监控.微计算机信息,2007,4(14):25-26
[16]朱军,金志刚.三层网络体系结构的特点和实现方法.电子工程师,2003,29(3):10-13
[17]Cen Nan,Faisal Khan.Real-time fault diagnosis using knowledge-based expert system.Process Safety and Environmental Protection,2008,86(11):55-71
[18]高明.故障诊断技术在矿山设备机械维修中的应用.内蒙古科技与经济,2006(12):164-166
[19]刘翠玲,黄建兵.集散控制系统.第1版.北京:北京大学版社,2006
[20]王贵成,宋琳,徐心和.一种基于PLC的远程监控系统的设计.微计算机信息,2005,21(7):116-118
[21]Boris V,Proto P,Anthony S.A Multithreaded Message Passing Interface(MPI)Architecture:Performance and Program Issues.Journal of Parallel and Distributed Computing,2001,4(26):61-69
[22]余华.基于PC-PLC的电梯远程监控系统的设计与实现.自动化与仪器仪表,2005(3):12-14
[23]Mano Ram Maurya,Raghunathan Rengaswamy.Fault diagnosis using dynamic trend analysis:A review and recent developments.Engineering Applications of Artificial Intelligence,2007,20(3):133-146
[24]莫兆祥,楚伟华.闸门自动化远程监控方式设计与分析.机电一体化,2008(1):89-92
[25]陆宝春,田先春,平晓锋,陈冬冬.混凝土砌块成型生产线的嵌入式智能监控与维护单元设计.中国制造业信息化,2007,19(36):58-62
[26]杨健,张慧慧.一种支持网络协议的嵌入式敏捷化智能维护单元的实现.高技术通讯,2006,16(2):67-71
[27]陆宝春,雷学东,周静.制造系统的智能监控和诊断.南京理工大学学报,2005,29(3):112-116
[28]谢志江,郭煜敬.分布式远程故障诊断平台研究.现代制造工程,2007(7):103-104,121
[29]Kajetanowicz M,Samek M,Sierpowski D,Stoehlker Th.Digital processing of Ge-detector signals.Radiation Physics and Chemistry,2006,75(9):1972-1976
[30]Jameel A,Siyal M,Ahmed N.Transform-domain and DSP based secure speech communication system.Microprocessors and Microsystems,2007,31:335-346
[31]向移山.基于MPEG-4的视频数字水印技术研究.燕山大学学报,2006,01:57-61
[32]周利,余愚.机械故障诊断中人工智能的应用.可编程控制器与工厂自动化(PLC FA),2007(7):36-38,40
[33]Joe A,Tseng C.A GSM-based remote wireless automatic monitoring system for field information:A case study for ecological monitoring of the oriental fruit fly, Bactrocera dorsalis.Computers and Electronics in Agriculture,2008,1(3):243-259
[34]Ming-Chung Tang.Exploiting GSM short message service for ubiquitous accessing.Journal of Network and Computer Applications,2001,24(3):247-267
[35]Jaewon Kang,Badri Nath.A study on switching voice traffic seamlessly between GSM and GPRS cellular networks.Computer Communications,2006,29(6):1079-1093
[36]Goma J,Mario Z.GSM wireless solutions in distributed embedded systems designed for automatic control.ELMAR,2004,6(22):14-16
[37]别丽华,蒋天发.柔性制造监测监控技术.武汉理工大学学报,2002,30(3):474-477
[38]Siemens A G.TC35/TC37 Siemens Cellular Engines Hardware Interface Description.Siemens AG,2002
[39]Pravin P,Bert-Jan van Beijnum,Marten van Sinderen.Performance Evaluation of the Context-Aware Handover Mechanism for the Nomadic Mobile Services in Remote Patient Monitoring.Computers and Electronics in Agriculture,2008,7(10):243-259
[40]宋超,李欣,董静薇.基于TC35i的无线数据采集系统.哈尔滨理工大学学报,2007,12(2):103-106
[41]李鸣,魏震生.武器装备远程分布式测试与诊断系统的研究及实现.测控技术,2006,25(12):10-13
[42]席晨飞,蔡慧林.基于GSM短消息与PLC的远程气象监测系统.自动化技术与应用,2007,26(11):43-45
[43]马潮.嵌入式GSM短消息接口的软硬件设计.单片机与嵌入式系统应用,2002(7):25-28
[44]魏英钦,陈连坤.基于TC35i的PC机短消息收发模块.电子世界,2007(2):22-24
[45]郭瑞军,谢晗昕,唐邦民.Visual Basic数据库开发实例精粹.第2版.北京:兵器工业出版社,2007
[46]张松林.机械产品两种模块化设计方法.交通与计算机.2001.19(3):621-64
[47]Tiit Kutser,Liisa Metsamaa.Influence of the vertical distribution of bacteria in the water column on the remote sensing signal.Estuarine Coastal and Shelf Science,2007,24(13):1016-1021
[48]Black U D.TCP/IP and Related Protocols.McGraw-Hill,1995,1:1-4
[49]任强,张华伟.WinSock网络编程技术在数控系统远程监控中的应用.机电工程技术,2007,36(8):69-71
[50]李春葆,刘圣才,张植民.Visual Basic程序设计.第1版.北京:清华大学出版社,2005
[51]Guan J,Braham J H.An integrated approach for fault diagnosis with learning.Computers in Industry,1996(32):33-51
[52]吴今培,肖健华.智能故障诊断与专家系统.第2版.北京:科学出版社,1997
[53]Marko Knezevic,Surya R.Kalidindi,David Fullwood.Computationally efficient database and spectral interpolation for fully plastic Taylor-type crystal plasticity calculations of face-centered cubic polycrystals.International Journal of Plasticity,2008,24(2):1264-1276
[54]Mahesh Kumar Jar,Garg P K.Monitoring and modelling of urban sprawl using remote sensing and GIS techniques.International Journal of Applied Earth Observation and Geoinformation,2008,10(7):26-43
[55]Q Gao,C Duan,H Fan.Rotating machine fault diagnosis using empirical mode decomposition.Mechanical Systems and Signal Processing,2008,22(9):1072-1081
[56]姚巍.Visual Basic数据库开发及工程实例.第1版.北京:人民邮电出版社,2003
[57]朱大奇,刘永安.故障诊断的信息融合方法.控制与决策,2007,22(12):1321-1328
[58]梁涛,马爱龙.具有远程监控功能的换热站自动控制系统.电子应用技术,2007,33(10):93-96
[59]李芳,贺雨田.基于VB的液压在线监测与故障诊断仪的上位机软件设计.石油仪器,2008,22(1):90-92
[60]陆明春,张学启.一种大型旋转机械远程在线监测和故障诊断系统.天津冶金,2008(1):55-57