阅读说明：本技术 一种皮带秤速度传感器的故障诊断方法 (Fault diagnosis method for belt scale speed sensor ) 是由 赖军荣 敖桂斌 谭晖 曾敏学 于 2021-09-10 设计创作，主要内容包括：本发明公开了一种皮带秤速度传感器的故障诊断方法,包括如下步骤：步骤1：在皮带秤的流量瞬时值为零时,通过采集皮带秤称重传感器的载荷值数据判断皮带秤所处状态；步骤2：根据皮带机的所处状态结合采集的速度传感器的脉冲信号状态来判断皮带秤速度传感器是否存在故障。本发明的优点在于：可以准确可靠的实现速度传感器的故障诊断；能够及时的输出报警信号,同时还能在一定情况下判断出皮带秤仪表的故障,故障分析更加准确可靠；故障分析基于皮带秤的载荷数据和速度传感器的脉冲数据,未新增加硬件结构或监测点,不会增加硬件成本同时也不会增加新的故障点,仅通过现有皮带机的数据进行上位机软件分析,并不涉及硬件,成本低,实现方便。(The invention discloses a fault diagnosis method of a belt scale speed sensor, which comprises the following steps: step 1: when the flow instantaneous value of the belt scale is zero, judging the state of the belt scale by collecting the load value data of a weighing sensor of the belt scale; step 2: and judging whether the speed sensor of the belt weigher has a fault or not according to the state of the belt conveyor and the acquired pulse signal state of the speed sensor. The invention has the advantages that: the fault diagnosis of the speed sensor can be accurately and reliably realized; the belt scale instrument fault diagnosis device can output alarm signals in time, and can judge the fault of the belt scale instrument under certain conditions, so that the fault analysis is more accurate and reliable; the fault analysis is based on the load data of the belt weigher and the pulse data of the speed sensor, a hardware structure or a monitoring point is not newly added, the hardware cost is not increased, a new fault point is not added at the same time, the upper computer software analysis is carried out only through the data of the existing belt conveyor, the hardware is not involved, the cost is low, and the realization is convenient.)

1. A fault diagnosis method for a belt scale speed sensor is characterized by comprising the following steps: the method comprises the following steps:

step 1: when the flow instantaneous value of the belt scale is zero, judging the state of the belt scale by collecting the load value data of a weighing sensor of the belt scale;

step 2: and judging whether the speed sensor of the belt weigher has a fault or not according to the state of the belt conveyor and the acquired pulse signal state of the speed sensor.

2. The method of claim 1, wherein the method further comprises the steps of: in the step 1, the belt weigher is in a running state and a shutdown state.

3. The method of claim 1, wherein the method further comprises the steps of: the method for judging whether the speed sensor of the belt scale has faults in the step 2 comprises the following steps: and when the belt conveyor is judged to be in the running state and no pulse signal of the speed sensor exists, judging that the speed sensor is in fault.

4. The method of claim 1, wherein the method further comprises the steps of: in step 1, the method for judging the state of the belt scale comprises the following steps:

when the flow instantaneous value of the belt scale is zero, the load value of the belt weighing sensor and the load value of the belt weighing sensor at intervals of set time are immediately acquired, the difference value obtained by subtracting the load value of the belt weighing sensor and the load value of the belt weighing sensor is compared with the set difference threshold value, when the difference value is smaller than the set difference threshold value, the belt is judged to be in a stop state, and otherwise, the belt is judged to be in a running state.

5. The method of claim 4, wherein the method further comprises the steps of: the setting method of the difference threshold value comprises the following steps: the following data were obtained in advance using a normal belt scale:

acquiring a plurality of effective load data of a belt scale weighing sensor in an empty scale shutdown state, and solving a difference value A between a maximum value and a minimum value;

acquiring a plurality of effective load data of a belt scale weighing sensor in an empty scale running state, and solving a difference value B between a maximum value and a minimum value;

and taking the average value obtained by summing the obtained difference A and the obtained difference B as the set difference threshold value.

6. A method of diagnosing a malfunction of a belt scale speed sensor as recited in claim 3, wherein: and when the belt conveyor is judged to be in the running state and no pulse signal of the speed sensor exists, judging that the belt weigher instrument is in the fault state.

7. The method of claim 1, wherein the method further comprises the steps of: the method further comprises step 3: and outputting a speed sensor fault alarm signal after judging the speed sensor fault for sending alarm prompt.

Technical Field

The invention relates to the field of fault detection, in particular to a fault diagnosis method for a belt scale speed sensor.

Background

The belt weigher speed sensor is an important part of the Siemens belt weigher, when the Siemens speed sensor is damaged or the Siemens speed sensor breaks down, the instantaneous flow and the accumulated flow data of Siemens stop material metering or intermittently perform material metering, and are not easy to find, thus seriously affecting the accuracy of the related units on the total material metering amount and leading the metering department to face the risk of metering doubt.

The Siemens speed sensing signal is a pulse signal, when the Siemens speed sensing device works, the pulse signal and some parameter values of the instrument act simultaneously to obtain instantaneous flow, and the working condition of the speed sensor cannot be judged in time and space only through the pulse signal, and the quality of the speed sensor cannot be judged completely.

Because the metering of the belt weigher and the operation of the belt do not belong to the same unit and department, the starting and stopping time of the belt cannot be accurately known, a belt operation detection device is additionally arranged, fault points are increased, and if the belt operation detection device is damaged, the monitoring of the starting and stopping of the belt cannot be well realized. Therefore, if the speed sensor fails, an alarm function is not provided, and the speed sensor cannot timely find that a blind area is formed on monitoring and diagnosis, and when the failure is found, the failure is probably within hours or days, so that a large amount of materials are not timely metered, the performance and the material ratio of relevant positions are influenced, even the whole production process and the product quality are influenced, and the speed sensor of the belt scale needs to be subjected to failure real-time monitoring.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provides a fault diagnosis method and a fault diagnosis system for a belt scale speed sensor, which are used for accurately monitoring the fault state of the belt scale speed sensor in real time.

In order to achieve the purpose, the invention adopts the technical scheme that: a fault diagnosis method for a belt scale speed sensor comprises the following steps:

step 1: when the flow instantaneous value of the belt scale is zero, judging the state of the belt scale by collecting the load value data of a weighing sensor of the belt scale;

step 2: and judging whether the speed sensor of the belt weigher has a fault or not according to the state of the belt conveyor and the acquired pulse signal state of the speed sensor.

In the step 1, the belt weigher is in a running state and a shutdown state.

The method for judging whether the speed sensor of the belt scale has faults in the step 2 comprises the following steps: and when the belt conveyor is judged to be in the running state and no pulse signal of the speed sensor exists, judging that the speed sensor is in fault.

In step 1, the method for judging the state of the belt scale comprises the following steps:

when the flow instantaneous value of the belt scale is zero, the load value of the belt weighing sensor and the load value of the belt weighing sensor at intervals of set time are immediately acquired, the difference value obtained by subtracting the load value of the belt weighing sensor and the load value of the belt weighing sensor is compared with the set difference threshold value, when the difference value is smaller than the set difference threshold value, the belt is judged to be in a stop state, and otherwise, the belt is judged to be in a running state.

The setting method of the difference threshold value comprises the following steps: the following data were obtained in advance using a normal belt scale:

acquiring a plurality of effective load data of a belt scale weighing sensor in an empty scale shutdown state, and solving a difference value A between a maximum value and a minimum value;

acquiring a plurality of effective load data of a belt scale weighing sensor in an empty scale running state, and solving a difference value B between a maximum value and a minimum value;

and taking the average value obtained by summing the obtained difference A and the obtained difference B as the set difference threshold value.

And when the belt conveyor is judged to be in the running state and no pulse signal of the speed sensor exists, judging that the belt weigher instrument is in the fault state.

The method further comprises step 3: and outputting a speed sensor fault alarm signal after judging the speed sensor fault for sending alarm prompt.

The invention has the advantages that: the fault diagnosis of the speed sensor can be accurately and reliably realized; the belt scale instrument fault diagnosis device can output alarm signals in time, and can judge the fault of the belt scale instrument under certain conditions, so that the fault analysis is more accurate and reliable; the fault analysis is based on the load data of the belt weigher and the pulse data of the speed sensor, a hardware structure or a monitoring point is not newly added, the hardware cost is not increased, a new fault point is not added at the same time, the upper computer software analysis is carried out only through the data of the existing belt conveyor, the hardware is not involved, the cost is low, and the realization is convenient.

Drawings

The contents of the expressions in the various figures of the present specification and the labels in the figures are briefly described as follows:

FIG. 1 is a flow chart of a fault diagnosis method of the present invention.

Detailed Description

The following description of preferred embodiments of the invention will be made in further detail with reference to the accompanying drawings.

The invention mainly utilizes the relevance of instantaneous data display of a belt scale speed sensor and a weighing sensor matched with the belt scale speed sensor in a BW500 integrating instrument and pulse signals of the speed sensor when a belt runs and stops, and judges the running or stopping state of the belt at that time, the state of an empty scale and the state of a material when the weighing sensor is stressed by upper software according to the instantaneous value of the belt scale and the gravity difference value of the weighing sensor when the belt is stressed, thereby diagnosing the working state of the speed sensor at that time and judging whether faults and damage phenomena exist.

As shown in fig. 1, a method for diagnosing a malfunction of a speed sensor of a belt scale includes the steps of:

s1: judging whether the current flow value of the belt scale is zero, if so, not starting a fault diagnosis algorithm, if so, starting a fault diagnosis step, starting fault diagnosis, and entering an S2 step;

s2, judging whether the segmented load value is larger than a standard value, and judging whether the belt scale is in a stopped state or an operating state; the sectional load value is that when the flow instantaneous value of the belt scale is zero, the load value of the belt weighing sensor and the load value of the belt weighing sensor at set time intervals are obtained immediately, the difference value obtained by subtracting the load value of the belt weighing sensor and the load value of the belt weighing sensor is the sectional load value, and the sectional load value is compared with the set difference threshold value to judge whether the belt scale is in the running state or the shutdown state. And when the difference value is smaller than the set difference value threshold value, judging that the belt is in a stop state, otherwise, judging that the belt is in a running state.

When the time-share load value is larger than the standard value, the working state is in the working state, and the step S3 is entered;

s3, acquiring an output pulse signal of the speed sensor, judging that the weighing instrument has a fault if the speed sensor outputs a valid pulse signal, and outputting a fault alarm signal of the weighing instrument to an upper computer; otherwise, the speed sensor fault is judged, and a speed sensor fault alarm signal is output to the upper computer, so that the alarm diagnosis and uploading are realized. In this application, when judging that the belt feeder is in running state and no speed sensor pulse signal, then judge for the speed sensor trouble. And when the belt conveyor is judged to be in the running state and no pulse signal of the speed sensor exists, judging that the belt weigher instrument is in the fault state.

The calculation method of the standard value is obtained by carrying out data measurement statistics on a normal belt conveyor in advance, and comprises the following specific steps:

the following data were obtained in advance using a normal belt scale:

acquiring a plurality of effective load data of a belt scale weighing sensor in an empty scale shutdown state, and solving a difference value A between a maximum value and a minimum value;

acquiring a plurality of effective load data of a belt scale weighing sensor in an empty scale running state, and solving a difference value B between a maximum value and a minimum value;

and taking the average value obtained by summing the obtained difference A and the obtained difference B as the set difference threshold value (A + B)/2.

The working principle is as follows: 1. the detection conditions are as follows: when the instantaneous flow is 0 (when the belt weigher stops or the speed sensor fails, the instantaneous flow is 0, and other time intervals have certain numerical values which are in direct proportion to the flow of the materials)

When the belt is stopped, the instantaneous flow is 0;

② when the speed sensor is damaged, the instantaneous flow is equal to 0

No detection under normal working state

2. The judgment basis is as follows: load value of sensor

Firstly, when the load value of the sensor is in the air balance, the output drift amounts of the sensor in different time periods are different, but the difference value between the output drift amounts is smaller, and the difference value of the drift amounts of the sensor in different time periods is larger than that of the sensor in the idle state of the air balance when the air balance is in the idle state

Secondly, the load value of the sensor increases along with the material flow, and the output drift amount of the sensor in different time periods is larger.

3. The meaning and principle of the standard value are as follows: the standard value is mainly a comparison value of output values of the load sensors when the vehicle is stopped or the speed sensor is in fault, so that whether the vehicle is in a shutdown state or in an operating state is distinguished.

If the empty scale is in a shutdown state, the instantaneous flow is 0, and the output load value drift amount is smaller than a standard value, so that no alarm occurs.

If the speed sensor is in fault, the instantaneous flow is 0, and the load value drift output by the sensor of the running belt scale is certainly greater than the standard value, so that an alarm can be prompted

1. And acquiring 10-100 effective load data of the belt scale weighing sensor in an empty scale shutdown state, and solving the difference between the maximum value and the minimum value. The more the number of the taken payloads is, the higher the precision is; the number can be adjusted according to actual requirements.

2. Acquiring 10-100 effective load data of a belt scale weighing sensor in an empty scale running state, and solving a difference value between a maximum value and a minimum value. The more the number of the taken payloads is, the higher the precision is; the number can be adjusted according to actual requirements.

3. And taking the average value of the sum of the dead weight state of the belt scale weighing sensor and the load range of the empty scale running state as a standard value for judging the fault of the speed sensor.

The standard value is the drift amount between different time periods of the output value of the weighing sensor in the shutdown state and the running state of the empty scale,

drift amount of weighing sensor output value in different time periods in operation state of empty scale > drift amount of weighing sensor output value in different time periods in shutdown state of empty scale

Taking the average between them would equal: empty scale stop < standard value < empty scale operation < load operation.

Firstly, an alarm is prevented when the empty scale is in a shutdown state.

And secondly, when the speed sensor fails, alarming can be realized under the running state of the empty scale and the running state of the material.

4. Under the condition that the instantaneous value of the belt weigher is zero, the upper computer software acquires the load value of a belt weigher weighing sensor every two seconds to carry out difference operation, the calculated difference value is compared with the standard value, if the difference value is smaller than the standard value, the belt can be judged to be in a stop state, and if the difference value is larger than the standard value, the belt can be judged to be in an operating state, so that the reason that no instantaneous flow exists can be caused by the reason of a speed sensor or the reason of a BW500 meter.

5. And acquiring a valid pulse signal of the speed sensor in a period, wherein if the pulse signal indicates that the speed sensor is normal, the valid pulse signal can be caused by the fault of the weighing instrument, and if the pulse signal does not exist, the valid pulse signal indicates that the speed sensor is caused by the fault of the weighing instrument.

The invention has the beneficial effects that: the realization of the belt scale speed sensor remote software diagnosis technology enables the belt speed sensor to be in fault, namely intermittent fault or completely damaged fault, to realize alarm recording and diagnosis timely and accurately in practical application, so that monitoring personnel can accurately judge the fault reason through the alarm recording in combination with video recording, and inform maintenance personnel to maintain on site timely at the first time, thereby reducing the measurement doubt of related units.

The scheme of the application successfully realizes the situation that the electronic belt scale speed sensor is in the early warning state of failure damage, the pulse signal is sometimes not in the early warning state, and the electronic belt scale has no warning function of any pulse signal after being completely damaged by field application, so that the phenomenon that the electronic belt scale has no metering accumulated value is timely discovered and maintained.

It is clear that the specific implementation of the invention is not restricted to the above-described embodiments, but that various insubstantial modifications of the inventive process concept and technical solutions are within the scope of protection of the invention.