技术领域technical field
本发明属于物联网应用领域，特别是能够利用工业嵌入式系统和GPRS无线传输来实现采集数据的传输，利用云服务器储存与处理，并通过软件进行数据分析，得到机床的运行状态、能耗、效率分析，真正实现远程监控。The invention belongs to the application field of the Internet of Things, and in particular can realize the transmission of collected data by using an industrial embedded system and GPRS wireless transmission, use a cloud server for storage and processing, and perform data analysis through software to obtain the running state, energy consumption, Efficiency analysis, real remote monitoring.
背景技术Background technique
锻压机床是金属和机械冷加工用的设备，一般比较大型且复杂，加工工艺多样。一旦机床发生故障，维修的专业性比较强，而且会影响加工产品的质量，甚至会导致事故的发生。因此对锻压机床进行状态监测，以对可能发生的故障实现预警是十分重要的。传统的锻压机床监测与故障诊断的实现是采用现场读取仪器仪表，再根据记录的数据人工进行故障诊断，企业常常为此花费大量人力财力。随着工业4.0时代的到来，物联网与大数据分析技术不断完善，应用领域也愈发广泛，机械控制工业的发展迎来了新的局面。目前，已处于将物联网技术应用于机床设备的监控中的大规模萌发阶段，物联网技术的应用使得机床的联网与在线监测成为可能，从而大大降低了人力、物力的投入。Forging machine tools are equipment for metal and mechanical cold processing. They are generally large and complex, and have various processing techniques. Once the machine tool fails, the maintenance is more professional, and it will affect the quality of the processed products, and even lead to accidents. Therefore, it is very important to monitor the condition of the forging machine tool to realize early warning of possible failures. The realization of traditional forging machine monitoring and fault diagnosis is to use on-site reading of instruments and meters, and then manually perform fault diagnosis according to the recorded data. Enterprises often spend a lot of manpower and financial resources for this. With the advent of the era of Industry 4.0, the Internet of Things and big data analysis technologies have been continuously improved, and the application fields have become more and more extensive. The development of the mechanical control industry has ushered in a new situation. At present, it is in the large-scale germination stage of applying the Internet of Things technology to the monitoring of machine tools. The application of the Internet of Things technology makes the networking and online monitoring of machine tools possible, thus greatly reducing the input of manpower and material resources.
但是目前基于物联网技术的机床数据采集与分析方法主要是基于PC平台的，网络通信方式多是PC平台的有线网络通信方式，还存在一些问题。比如：采集平台多依赖于PC平台，普通计算机的体积大、功耗高、不适于恶劣环境工作，且成本比较高；对采集数据使用不够充分，缺乏深层次的信息挖掘；实时性有待进一步提高等。However, the current machine tool data collection and analysis methods based on the Internet of Things technology are mainly based on the PC platform, and the network communication method is mostly the wired network communication method of the PC platform, and there are still some problems. For example, the acquisition platform is mostly dependent on the PC platform. The ordinary computer has large size, high power consumption, is not suitable for working in harsh environments, and the cost is relatively high; the use of the acquired data is not sufficient, and there is a lack of in-depth information mining; the real-time performance needs to be further improved Wait.
现有专利文献CN102566503A中公开了一种数控机床远程监控与故障诊断系统，该系统利用传感器采集机床的状态信息数据，并通过GPRS网络将数据传输到远程服务器，由服务器中的服务管理与专家系统模块对传输过来的数据进行处理，获得处理结果并返回给故障机床，实现对数控机床的远程监控与故障诊断。该系统的不足在于所述远程服务器的数据管理复杂，存储空间有限，缺乏弹性的空间扩展能力，不能自动产生机床运行报告，用户使用数据不便捷。The existing patent document CN102566503A discloses a remote monitoring and fault diagnosis system for CNC machine tools. The system uses sensors to collect state information data of the machine tool, and transmits the data to a remote server through a GPRS network. The service management and expert system in the server The module processes the transmitted data, obtains the processing result and returns it to the faulty machine tool, so as to realize the remote monitoring and fault diagnosis of the CNC machine tool. The disadvantage of this system is that the data management of the remote server is complicated, the storage space is limited, the flexible space expansion capability is lacking, the machine tool operation report cannot be automatically generated, and the data is inconvenient for the user to use.
发明内容SUMMARY OF THE INVENTION
针对现有机床的数据采集与分析系统存在的问题，本发明提供了一种新的基于物联网技术的锻压机床运行工况信息采集与分析系统，采集平台依赖于基于ARM技术的工业嵌入式系统平台，实时性强、体积小、功耗低，适用于工业环境；数据传输采用GPRS网络，可以直接与Internet互通，网络传输速率高，保证了数据的时效性；数据存储与处理采用的是云服务器，数据管理的难度降低，扩展存储空间与数据访问便捷。Aiming at the problems existing in the data acquisition and analysis system of the existing machine tools, the present invention provides a new collection and analysis system for the operation condition information of the forging machine tool based on the Internet of Things technology. The acquisition platform depends on the industrial embedded system based on the ARM technology. The platform has strong real-time performance, small size and low power consumption, and is suitable for industrial environments; data transmission adopts GPRS network, which can directly communicate with the Internet, and the network transmission rate is high, which ensures the timeliness of data; data storage and processing adopts cloud Server, the difficulty of data management is reduced, and the expansion of storage space and data access is convenient.
为达到上述目的，本发明提供的技术方案为：In order to achieve the above object, the technical scheme provided by the invention is:
所述的锻压机床运行工况信息采集与分析系统由4大模块组成。如附图1所示，由虚线框框起来的四大模块分别是数据采集模块、数据传输模块、数据管理模块及数据共享模块。各模块设备主要包括传感器、PLC、嵌入式系统、GPRS DTU、云服务器和PC。The said forging machine tool operating condition information collection and analysis system consists of four modules. As shown in FIG. 1 , the four major modules framed by the dotted line are a data acquisition module, a data transmission module, a data management module and a data sharing module, respectively. Each module equipment mainly includes sensors, PLC, embedded system, GPRS DTU, cloud server and PC.
所述的数据采集模块主要包括位移传感器、温度传感器、电流传感器、液位传感器及 PLC。传感器主要用于采集包括主轴电流、主轴功率、温度等模拟量，通过对机床电器电路及PLC信号点的采集获取机床的通电状态、主轴启停、冷却液开关等信息。The data acquisition module mainly includes a displacement sensor, a temperature sensor, a current sensor, a liquid level sensor and a PLC. The sensor is mainly used to collect analog quantities including spindle current, spindle power, temperature, etc., and obtain information such as the power-on state of the machine tool, spindle start and stop, and coolant switch through the collection of machine tool electrical circuits and PLC signal points.
所述的数据传输模块主要包括嵌入式系统、GPRS DTU(General Packet RadioService Data Transfer unit)和移动网络通信。嵌入式系统接口电路用于将PLC的输入输出开关量信号及传感器的信号通过适当的信号处理及A/D转换传送给处理器芯片ARM。GPRSDTU用于与外界交换信息，可以将信号通过GSM移动通信连接到Internet，进而传到中心数据库。The data transmission module mainly includes embedded system, GPRS DTU (General Packet RadioService Data Transfer unit) and mobile network communication. The embedded system interface circuit is used to transmit the input and output switch signal of PLC and the signal of the sensor to the processor chip ARM through appropriate signal processing and A/D conversion. GPRSDTU is used to exchange information with the outside world, and the signal can be connected to the Internet through GSM mobile communication, and then transmitted to the central database.
所述的数据管理模块主要是云服务器集群，包括中心数据库、Web服务器和数据分析服务器，用于统一管理采集数据，并进行数据的分析处理，生成运行状态报告、产品能耗、效率等分析报告，方便数据的查询与共享。The data management module is mainly a cloud server cluster, including a central database, a web server and a data analysis server, which is used to manage the collected data in a unified manner, analyze and process the data, and generate analysis reports such as operating status reports, product energy consumption, and efficiency. , to facilitate data query and sharing.
所述的数据共享模块主要是个人计算机，用于数据的共享。一方面机床销售方的技术人员可根据数据的分析得到机床的运行状态，对可能出现的故障做出及时的判断，并可依此提出产品改进的方案，生成远程故障诊断报告和机床状态报告提供给客户；另一方面客户可以通过客户端程序随时查询，随时监控机床的运行状态。The data sharing module is mainly a personal computer, which is used for data sharing. On the one hand, the technicians of the machine tool seller can obtain the running status of the machine tool according to the data analysis, make timely judgments on possible faults, and can propose product improvement plans accordingly, generate remote fault diagnosis reports and machine tool status reports to provide To customers; on the other hand, customers can inquire at any time through the client program to monitor the running status of the machine tool at any time.
所述系统信息传递的步骤：The steps of the system information transmission:
(1)在锻压机床上布置位移传感器、温度传感器、电流传感器及液位传感器等，利用传感器感知机床主轴电流、温度等模拟量信息。这些信息包含了丰富的机床状态信息，如相关刀具磨损状态、机床振动信号、机床的能耗、故障异常等重要信息。(1) Displacement sensors, temperature sensors, current sensors and liquid level sensors are arranged on the forging machine tool, and the sensors are used to sense the analog information such as the current and temperature of the machine tool spindle. This information contains a wealth of machine tool status information, such as relevant tool wear status, machine tool vibration signals, machine tool energy consumption, fault exceptions and other important information.
(2)对PLC的信号点采集开关量信息。通过读取PLC的I/O状态，来获取机床的通电状态、主轴启停、冷却液开关等信息。(2) Collect the switch quantity information for the signal point of PLC. By reading the I/O status of the PLC, information such as the power-on status of the machine tool, spindle start and stop, and coolant switch can be obtained.
(3)嵌入式系统的接口电路将所述步骤(1)、步骤(2)中传感器与PLC的信号通过适当的处理(如滤波、电平转换、A/D转换等)转换成处理器芯片可接受的信号，传送到芯片的输入端口，然后通过驱动GPRS通讯模块，由GPRS无线网络连接到Internet，进而传到中心数据库。所述的GPRS通讯模块为远端站GPRS DTU，DTU开机时自动连接GPRS 网络，通过GPRS网络将数据定时发往指定数据库的数据中心，数据中心在收到DTU的数据后，进行协议转换还原用户数据，数据中心可从Internet接入。(3) The interface circuit of the embedded system converts the signals of the sensor and the PLC in the steps (1) and (2) into a processor chip through appropriate processing (such as filtering, level conversion, A/D conversion, etc.) The acceptable signal is transmitted to the input port of the chip, and then connected to the Internet by the GPRS wireless network by driving the GPRS communication module, and then transmitted to the central database. The GPRS communication module is a remote station GPRS DTU. When the DTU is turned on, it is automatically connected to the GPRS network, and the data is regularly sent to the data center of the designated database through the GPRS network. After receiving the data of the DTU, the data center performs protocol conversion to restore the user. Data, the data center can be accessed from the Internet.
(4)云服务器集群包括中心数据库、Web服务器和数据分析服务器。中心数据库将接收所述步骤(3)中远端站GPRS DTU传来的数据；Web服务器将管理及存储这些信息，便于用户的查询；数据分析服务器将通过内部的软件对中心数据库的数据进行分析，自动产生机床的运行状态报告、产品能耗、效率等分析报告。(4) The cloud server cluster includes a central database, a web server and a data analysis server. The central database will receive the data from the remote station GPRS DTU in the step (3); the Web server will manage and store these information, which is convenient for users to query; the data analysis server will analyze the data in the central database through the internal software , automatically generate the running status report of the machine tool, product energy consumption, efficiency and other analysis reports.
(5)所述步骤(4)中产生的机床运行状态、产品能耗、效率等报告存储在云服务器，授权用户可在计算机上登录系统进行查询。一方面机床销售方技术人员可查询机床工作曲线、能耗等报告，随时掌握机床的运行状态，也可通过故障诊断模块对数据进行进一步的分析，对机床可能发生的故障做出及时的判断，实现远程故障诊断，并提出故障应对决策；另一方面，机床客户可通过客户端软件随时监控产品的运行状态，得到产品的能耗、效率等基本信息，也可从技术人员那里获取远程故障诊断报告及故障应对决策等。(5) Reports such as machine tool running status, product energy consumption, and efficiency generated in the step (4) are stored in the cloud server, and authorized users can log in to the system on a computer to inquire. On the one hand, the technicians of the machine tool sales side can inquire about the working curve, energy consumption and other reports of the machine tool, grasp the running status of the machine tool at any time, and can further analyze the data through the fault diagnosis module to make timely judgments on the possible faults of the machine tool. Realize remote fault diagnosis and make fault response decisions; on the other hand, machine tool customers can monitor the running status of the product at any time through the client software, obtain basic information such as energy consumption and efficiency of the product, and obtain remote fault diagnosis from technicians. Reports and fault response decisions, etc.
采用本发明提供的技术方案，与现有技术相比，具有如下优点：Compared with the prior art, the technical scheme provided by the present invention has the following advantages:
(1)采集平台依赖于基于ARM技术的工业嵌入式系统平台，实时性强、体积小、功耗低，适用于工业环境。(1) The acquisition platform relies on the industrial embedded system platform based on ARM technology, which has strong real-time performance, small size and low power consumption, and is suitable for industrial environments.
(2)每台机床具备独立联网能力，不依赖客户企业内网。(2) Each machine tool has independent networking capability and does not rely on the customer's enterprise intranet.
(3)数据传输采用GPRS无限网络，避免了铺设光纤、电缆的工作，并可对销售到各地的机床进行网络连接，并可直接与Internet互通，网络传输速率高，保证了数据的时效性，实现了数据的实时采集与上传。(3) The data transmission adopts GPRS wireless network, which avoids the work of laying optical fibers and cables, and can connect the machine tools sold to various places to the network, and can directly communicate with the Internet. The network transmission rate is high, which ensures the timeliness of data. Real-time data collection and uploading are realized.
(4)数据存储与处理采用的是云服务器，数据管理的难度降低，扩展存储空间方便，数据访问便捷，真正实现了远程监控。(4) The cloud server is used for data storage and processing, which reduces the difficulty of data management, facilitates expansion of storage space, and facilitates data access, which truly realizes remote monitoring.
附图说明Description of drawings
图1为方法所涉及的装置的组成框图。FIG. 1 is a block diagram of the apparatus involved in the method.
图2为系统的信息流程图。Figure 2 is an information flow diagram of the system.
具体实施方式Detailed ways
为进一步了解本发明的内容，结合附图和实施例对本发明作详细描述。In order to further understand the content of the present invention, the present invention will be described in detail with reference to the accompanying drawings and embodiments.
结合附图1，目前本发明装置中的嵌入式系统采用的是Broadcom BCM2835 700MHzARM1176JZFS处理器，带FPU和Video Core IV双核GPU；服务器端CPU为单颗Intel Xeon E5-2400、支持双CPU；客户端CPU为Intel Core i3。With reference to Figure 1, the embedded system in the device of the present invention currently adopts a Broadcom BCM2835 700MHzARM1176JZFS processor with FPU and Video Core IV dual-core GPU; the server-side CPU is a single Intel Xeon E5-2400, which supports dual CPUs; the client The CPU is Intel Core i3.
由位移传感器、温度传感器、电流传感器、液位传感器及PLC采集机床的运行状态信息。传感器主要采集包括主轴电流、主轴功率、温度等模拟量，通过对机床电器电路及PLC信号点的采集获取机床的通电状态、主轴启停、冷却液开关等信息；The running state information of the machine tool is collected by displacement sensor, temperature sensor, current sensor, liquid level sensor and PLC. The sensor mainly collects analog quantities including spindle current, spindle power, temperature, etc., and obtains the power-on state of the machine tool, spindle start and stop, coolant switch and other information through the collection of machine tool electrical circuits and PLC signal points;
所述数据传输模块的工作原理与工作过程是：嵌入式系统的接口电路将上述传感器与 PLC的信号通过适当的处理(如滤波、电平转换、A/D转换等)转换成处理器芯片可接受的信号，传送到芯片BCM2835ARM，然后通过驱动GPRS通讯模块，由GPRS无线网络连接到Internet，进而传到中心数据库。所述的GPRS通讯模块为远端站GPRS DTU，DTU必须内置相关处理协议栈，以完成用户设备的接口协议转换，同时必须具备异常和容错处理的功能，DTU选择CMNET接入Internet与数据中心进行数据交互。The working principle and working process of the data transmission module are as follows: the interface circuit of the embedded system converts the signals of the above-mentioned sensors and PLC through appropriate processing (such as filtering, level conversion, A/D conversion, etc.) The received signal is transmitted to the chip BCM2835ARM, and then connected to the Internet by the GPRS wireless network by driving the GPRS communication module, and then transmitted to the central database. The GPRS communication module is a remote station GPRS DTU. The DTU must have a built-in related processing protocol stack to complete the interface protocol conversion of the user equipment. At the same time, it must have the functions of abnormal and fault-tolerant processing. Data interaction.
云服务器集群包括中心数据库、Web服务器和数据分析服务器，主要负责统一管理采集数据，其特征是高度分布式、高度虚拟化，使得网络资源得到充分的利用。中心数据库接受上述远端站GPRS DTU传来的信息。数据分析服务器通过内部的软件对数据进行分析，得到机床的运行状态报告、产品能耗、效率等分析报告。一方面，机床销售方的技术人员可查询机床的运行报告及时了解机床的运行状态，对可能出现的故障做出及时的判断，从而实现远程故障诊断，并提出故障应对决策提供给机床用户；另一方面，机床的使用客户可通过访问Web服务器，随时监控产品的运行状态，得到产品的能耗、效率等基本信息，也可从技术人员那里获取远程故障诊断报告及故障应对决策等。The cloud server cluster includes a central database, a web server and a data analysis server, which is mainly responsible for the unified management of the collected data. The central database accepts the information from the above-mentioned remote station GPRS DTU. The data analysis server analyzes the data through the internal software, and obtains analysis reports such as the running status report of the machine tool, product energy consumption, and efficiency. On the one hand, the technicians of the machine tool seller can check the operation report of the machine tool to know the running status of the machine tool in time, and make timely judgments on possible faults, so as to realize remote fault diagnosis, and propose fault response decisions to the machine tool users; On the one hand, customers who use the machine tool can access the Web server to monitor the running status of the product at any time, obtain basic information such as energy consumption and efficiency of the product, and obtain remote fault diagnosis reports and fault response decisions from technicians.
图2为系统的信息流程图，结合附图2，本系统信号传递的过程是：机床外接传感器和 PLC采集机床运行的数据，通过外接电路将数据传送到嵌入式系统的处理器芯片，处理器对信号进行放大、滤波后，通过通信接口，上传到无线数据终端。数据终端通过GPRS网络与移动网络进行远程数据传输，将数据传到云端。云服务器的软件对数据进行处理分析，以便于用户的查询。机床的用户可以随时访问云端数据，及时了解设备的运行状况。机床的维护技术人员可以根据云端的数据进行分析，做出故障诊断报告及应对的决策，提供给用户。Fig. 2 is the information flow chart of the system, in conjunction with Fig. 2, the process of signal transmission in this system is: the external sensor of the machine tool and the PLC collect the data of the machine tool operation, and the data is transmitted to the processor chip of the embedded system through the external circuit, and the processor After the signal is amplified and filtered, it is uploaded to the wireless data terminal through the communication interface. The data terminal performs remote data transmission through the GPRS network and the mobile network, and transmits the data to the cloud. The software of the cloud server processes and analyzes the data to facilitate the user's query. The user of the machine tool can access the cloud data at any time and keep abreast of the operation status of the equipment. The maintenance technicians of the machine tools can analyze the data in the cloud, make fault diagnosis reports and make corresponding decisions, and provide them to users.
| Application Number | Priority Date | Filing Date | Title |
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| CN201610330738.3ACN105785961B (en) | 2016-05-17 | 2016-05-17 | The information collection of forging machine tool operating condition and analysis system based on technology of Internet of things |
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| CN201610330738.3ACN105785961B (en) | 2016-05-17 | 2016-05-17 | The information collection of forging machine tool operating condition and analysis system based on technology of Internet of things |
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| CN201610330738.3AActiveCN105785961B (en) | 2016-05-17 | 2016-05-17 | The information collection of forging machine tool operating condition and analysis system based on technology of Internet of things |
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