技术领域Technical Field
本实用新型涉及工业自动控制技术领域，尤其涉及一种煤磨设备巡检系统。The utility model relates to the technical field of industrial automatic control, in particular to a coal mill equipment inspection system.
背景技术Background technique
煤磨机是水泥厂生产线上重要的机器设备，也是运行人员巡检的重要设备，巡检工作环境差、噪音大，需要上下攀爬，劳动强度大。现阶段水泥行业的检修数据、巡检数据基本以巡检人员手工记录为主(部分仪表还不具备数据采集功能)，未能与设备的各项控制数据做到融合应用。国内外对煤磨机的基于振动信号和振动特征库故障诊断研究比较普遍，但是此类方法必须针对各监测点位安装振动传感器，并且监测位置受限。随着信息技术的发展，智能巡检机器人在电力行业和石化中的大型发电机、风机和透平机等重点设备研究中使用，但在水泥行业尚未有使用案例。当前国内外对水泥厂巡检监控诊断的研究主要停留在设备的机械结构设计、生产工艺优化等方面，针对水泥生产线中煤磨设备运行状态监控和故障诊断的研究几乎很少。Coal mill is an important machine equipment on the production line of cement plant, and it is also an important equipment for operators to inspect. The inspection working environment is poor, the noise is loud, and it is necessary to climb up and down, which is labor-intensive. At present, the maintenance data and inspection data of the cement industry are mainly recorded manually by inspectors (some instruments do not have data collection functions), and they have not been integrated with the various control data of the equipment. Research on fault diagnosis of coal mills based on vibration signals and vibration feature libraries is relatively common at home and abroad, but such methods must install vibration sensors for each monitoring point, and the monitoring position is limited. With the development of information technology, intelligent inspection robots are used in the research of key equipment such as large generators, fans and turbines in the power industry and petrochemicals, but there are no use cases in the cement industry. At present, the research on inspection monitoring and diagnosis of cement plants at home and abroad mainly stays in the mechanical structure design of equipment, production process optimization and other aspects, and there is almost no research on the operation status monitoring and fault diagnosis of coal mill equipment in cement production lines.
实用新型内容Utility Model Content
针对现有技术存在的问题，本实用新型提供一种煤磨设备巡检系统，以解决现有技术中存在的巡检效率低下的问题。In view of the problems existing in the prior art, the utility model provides a coal mill equipment inspection system to solve the problem of low inspection efficiency existing in the prior art.
本实用新型提供一种煤磨设备巡检系统，所述煤磨设备的煤磨本体及主机设备设置在主体区域内，所述煤磨设备的辅助设备设置在辅机区域内，所述巡检系统包括：The utility model provides a coal mill equipment inspection system, wherein the coal mill body and the main machine equipment of the coal mill equipment are arranged in the main area, the auxiliary equipment of the coal mill equipment is arranged in the auxiliary machine area, and the inspection system comprises:
轨道，所述轨道围绕所述主体区域架设；A track, the track is set up around the main area;
用于根据预设的巡检任务对所述煤磨本体和所述主机设备进行监测的轨道机器人，所述轨道机器人与所述轨道滑动连接；A track robot for monitoring the coal mill body and the host equipment according to a preset inspection task, wherein the track robot is slidably connected to the track;
用于对所述辅助设备进行监测的辅助监测装置，所述辅助监测装置固设于所述辅机区域内；An auxiliary monitoring device for monitoring the auxiliary equipment, wherein the auxiliary monitoring device is fixedly arranged in the auxiliary machine area;
云端管理平台，所述云端管理平台与所述轨道机器人和所述辅助监测装置通信连接。A cloud management platform is communicatively connected with the track robot and the auxiliary monitoring device.
根据本实用新型提供的一种煤磨设备巡检系统，所述轨道机器人包括：According to a coal mill equipment inspection system provided by the utility model, the track robot comprises:
通信模块，所述通信模块用于基于巡检沿途区域部署的无线基站与所述云端管理平台通信连接；A communication module, the communication module is used to communicate with the cloud management platform based on wireless base stations deployed in the inspection area;
行走机构，所述行走机构用于驱动所述轨道机器人沿所述轨道滑动行走；A walking mechanism, the walking mechanism is used to drive the track robot to slide and walk along the track;
定位装置，所述定位装置用于沿所述轨道固定的RFID标签对所述轨道机器人进行全局定位和巡检点定位；A positioning device, the positioning device is used to perform global positioning and inspection point positioning of the track robot along the RFID tags fixed on the track;
采集装置，所述采集装置用于采集所述煤磨本体和所述主机设备的仪表数据和煤磨主电机的温度数据，上传至所述云端管理平台；A collection device, the collection device is used to collect instrument data of the coal mill body and the host equipment and temperature data of the coal mill main motor, and upload them to the cloud management platform;
供电模块，所述供电模块分别电连接所述通信模块、所述行走机构、所述定位装置和所述采集装置。A power supply module is electrically connected to the communication module, the walking mechanism, the positioning device and the collection device respectively.
根据本实用新型提供的一种煤磨设备巡检系统，所述采集装置包括：According to a coal mill equipment inspection system provided by the utility model, the collection device includes:
双目摄像头，所述双目摄像头用于对所述煤磨本体和所述主机设备的现场情况进行拍摄采集，以及在不同的巡检点对所述煤磨本体和所述主机设备的多个现场仪表的仪表数据进行拍摄采集；A binocular camera, the binocular camera is used to photograph and collect the on-site conditions of the coal mill body and the host equipment, and photograph and collect instrument data of multiple on-site instruments of the coal mill body and the host equipment at different inspection points;
红外热成像仪，所述红外热成像仪用于对所述煤磨设备的主电机进行温度监测。An infrared thermal imager is used to monitor the temperature of the main motor of the coal mill equipment.
根据本实用新型提供的一种煤磨设备巡检系统，所述辅助监测装置包括：According to a coal mill equipment inspection system provided by the utility model, the auxiliary monitoring device includes:
至少一个工业摄像头设于所述辅机区域，用于对所述辅助设备的运行情况进行拍摄采集，以及对所述辅助设备的仪表数据进行拍摄采集；At least one industrial camera is arranged in the auxiliary equipment area, and is used to photograph and collect the operation status of the auxiliary equipment, and photograph and collect the instrument data of the auxiliary equipment;
粉尘传感器，所述粉尘传感器设于所述辅机区域，用于对所述辅机区域的粉尘数据进行监测。A dust sensor is provided in the auxiliary machine area and is used for monitoring dust data in the auxiliary machine area.
根据本实用新型提供的一种煤磨设备巡检系统，所述轨道机器人包括：According to a coal mill equipment inspection system provided by the utility model, the track robot comprises:
轨道清扫毛刷，所述轨道清扫毛刷设置于所述轨道机器人与所述轨道的连接处。A track cleaning brush is arranged at the connection between the track robot and the track.
根据本实用新型提供的一种煤磨设备巡检系统，还包括：According to a coal mill equipment inspection system provided by the utility model, the system also includes:
至少一组充电桩和除尘装置，所述充电桩和所述除尘装置设置在所述轨道的一侧或两侧，并与所述轨道机器人的本体位置对应设置，所述充电桩设有定位传感器。At least one set of charging piles and dust removal devices, wherein the charging piles and the dust removal devices are arranged on one side or both sides of the track and are arranged corresponding to the main body position of the track robot, and the charging piles are provided with positioning sensors.
根据本实用新型提供的一种煤磨设备巡检系统，所述充电桩采用无线充电结构，具有电能发射装置，所述轨道机器人具有与所述电能发射装置对应设置的电能接收装置。According to a coal mill inspection system provided by the utility model, the charging pile adopts a wireless charging structure and has an electric energy transmitting device, and the rail robot has an electric energy receiving device arranged corresponding to the electric energy transmitting device.
根据本实用新型提供的一种煤磨设备巡检系统，所述除尘装置采用吹风机结构并安装固定在所述轨道的立柱组件上，所述除尘装置的出风口朝向所述轨道机器人的采集装置。According to a coal mill inspection system provided by the utility model, the dust removal device adopts a blower structure and is installed and fixed on the column assembly of the track, and the air outlet of the dust removal device faces the collection device of the track robot.
根据本实用新型提供的一种煤磨设备巡检系统，围绕所述主体区域设有若干个立柱组件，所述轨道通过所述立柱组件架设，每个所述立柱组件包括：According to a coal mill inspection system provided by the utility model, a plurality of column assemblies are arranged around the main body area, the track is erected through the column assemblies, and each of the column assemblies includes:
底板；Base plate;
所述底板固定安装于地面，所述底板上安装有支撑架；The bottom plate is fixedly installed on the ground, and a support frame is installed on the bottom plate;
所述支撑架的远离所述底板的一端安装有向外延伸的横梁；An outwardly extending crossbeam is installed at one end of the support frame away from the bottom plate;
所述横梁的端部设有吊挂所述轨道的连接件；The end of the crossbeam is provided with a connecting piece for hanging the track;
所述横梁与所述支撑架的上部通过斜撑架连接固定。The cross beam is connected and fixed to the upper part of the support frame through an oblique support frame.
根据本实用新型提供的一种煤磨设备巡检系统，所述轨道机器人还设有声光报警装置，用于根据所述轨道机器人和/或所述辅助监测装置的监测情况进行声光报警通知。According to a coal mill inspection system provided by the utility model, the rail robot is also provided with an audible and visual alarm device for making audible and visual alarm notifications according to the monitoring conditions of the rail robot and/or the auxiliary monitoring device.
本实用新型提供的一种煤磨设备巡检系统，利用轨道机器人对煤磨设备的煤磨本体及主机设备所在的主体区域进行现场巡检和监控，同时结合辅助监测装置实现了辅机区域的现场巡检和监控，实现了煤磨设备运行数据的精准自动采集和智能化在线监测，从而实现对设备故障的诊断，进而对煤磨设备维修提供指导，减少设备故障对生产造成的影响，为设备维修由定期维修向预知性维修转变提供支撑。有效提升了煤磨机的巡检效率，降低了设备宕机率和设备维护成本，确保企业的安全生产。The utility model provides a coal mill equipment inspection system, which uses a track robot to conduct on-site inspection and monitoring of the coal mill body and the main area where the main equipment of the coal mill equipment is located, and at the same time combines with an auxiliary monitoring device to realize on-site inspection and monitoring of the auxiliary area, and realizes accurate automatic collection and intelligent online monitoring of coal mill equipment operation data, thereby realizing the diagnosis of equipment failures, and then providing guidance for coal mill equipment maintenance, reducing the impact of equipment failures on production, and providing support for the transformation of equipment maintenance from regular maintenance to predictive maintenance. It effectively improves the inspection efficiency of coal mills, reduces equipment downtime and equipment maintenance costs, and ensures the safe production of enterprises.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
为了更清楚地说明本实用新型或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作一简单地介绍，显而易见地，下面描述中的附图是本实用新型的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.
图1是本实用新型实施例提供的煤磨设备巡检系统的结构示意图；FIG1 is a schematic structural diagram of a coal mill inspection system provided by an embodiment of the utility model;
图2是本实用新型实施例提供的煤磨设备巡检系统的轨道高度示意图；FIG2 is a schematic diagram of the track height of the coal mill equipment inspection system provided by the embodiment of the utility model;
图3是本实用新型实施例提供的煤磨设备巡检系统的立柱组件的结构示意图；3 is a schematic structural diagram of a column assembly of a coal mill inspection system provided by an embodiment of the utility model;
图4是本实用新型实施例提供的煤磨设备巡检系统的系统架构示意图；FIG4 is a schematic diagram of the system architecture of a coal mill equipment inspection system provided by an embodiment of the utility model;
图5是本实用新型实施例提供的煤磨设备巡检系统的轨道机器人的结构示意图；5 is a schematic diagram of the structure of a track robot of a coal mill inspection system provided by an embodiment of the present utility model;
图6是本实用新型实施例提供的基于煤磨设备巡检系统的巡检方法的流程示意图。FIG6 is a flow chart of an inspection method based on a coal mill equipment inspection system provided in an embodiment of the utility model.
附图标记说明：Description of reference numerals:
A：主体区域；B:门口；1：轨道；2：煤磨主机设备；3：轨道机器人；301：轨道清扫毛刷；302：通信模块；303：双目摄像头；304：补光灯；305：红外热成像仪；306：下位机烧录接口；307：上位机调试接口；308：三色指示灯；309：扬声器；310：电源开关；311：电能接收装置；4：高压润滑油站；5：立磨换热站；6：驱动电机；7：充电桩及除尘装置；8：立柱组件；81：底板；82：支撑架；83：横梁；84：连接件；85：斜撑架。A: Main area; B: Door; 1: Track; 2: Coal mill main equipment; 3: Track robot; 301: Track cleaning brush; 302: Communication module; 303: Binocular camera; 304: Fill light; 305: Infrared thermal imager; 306: Lower computer burning interface; 307: Upper computer debugging interface; 308: Three-color indicator light; 309: Speaker; 310: Power switch; 311: Power receiving device; 4: High-pressure lubricating oil station; 5: Vertical mill heat exchange station; 6: Driving motor; 7: Charging pile and dust removal device; 8: Column assembly; 81: Bottom plate; 82: Support frame; 83: Crossbeam; 84: Connector; 85: Diagonal support frame.
具体实施方式Detailed ways
为使本实用新型的目的、技术方案和优点更加清楚，下面将结合本实用新型中的附图，对本实用新型中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本实用新型一部分实施例，而不是全部的实施例。基于本实用新型中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本实用新型保护的范围。In order to make the purpose, technical solution and advantages of the utility model clearer, the technical solution of the utility model will be described clearly and completely in conjunction with the drawings in the utility model. Obviously, the described embodiments are part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.
针对水泥厂立煤磨设备半开放式的环境，下面结合图1-图6描述本实用新型的一种煤磨设备巡检系统。Aiming at the semi-open environment of vertical coal mill equipment in cement plants, a coal mill equipment inspection system of the present invention is described below in conjunction with FIGS. 1 to 6 .
实施例一Embodiment 1
参照图1所示，本实施例提供一种煤磨设备巡检系统，煤磨设备的煤磨本体2及主机设备(主机设备为煤磨本体2周边关键设备，如高压润滑油站4、立磨换热站5和驱动电机6等)设置在主体区域A，煤磨设备处于室外半封闭的现场主体区域，主体区域A围绕煤磨本体2及主机设备，煤磨设备的辅助设备设置在辅机区域(图中未示出，指的是室内单独的区域，如室内2层的窑头粉研秤、3层的软连接和4层的除尘灰斗等设置有辅助设备的区域)内，该巡检系统包括：As shown in FIG1 , this embodiment provides a coal mill equipment inspection system, the coal mill body 2 and the host equipment of the coal mill equipment (the host equipment is the key equipment around the coal mill body 2, such as the high-pressure lubricating oil station 4, the vertical mill heat exchange station 5 and the drive motor 6, etc.) are arranged in the main area A, the coal mill equipment is in the outdoor semi-enclosed on-site main area, the main area A surrounds the coal mill body 2 and the host equipment, and the auxiliary equipment of the coal mill equipment is arranged in the auxiliary machine area (not shown in the figure, referring to a separate area indoors, such as the kiln head powder grinding scale on the 2nd floor, the soft connection on the 3rd floor and the dust removal hopper on the 4th floor, etc., where auxiliary equipment is arranged), the inspection system includes:
轨道1，轨道1围绕主体区域A架设；Track 1, Track 1 is erected around the main area A;
用于根据预设的巡检任务对煤磨本体2及主机设备进行监测的轨道机器人，轨道机器人3与轨道1滑动连接；A track robot for monitoring the coal mill body 2 and the host equipment according to a preset inspection task, the track robot 3 being slidably connected to the track 1;
用于对辅助设备进行监测的辅助监测装置(图中未标示，辅助设备的点位分散，对其进行监测的辅助监测装置的点位也分散设置)，辅助监测装置固设于辅机区域内；Auxiliary monitoring devices for monitoring auxiliary equipment (not shown in the figure, the auxiliary equipment is dispersed, and the auxiliary monitoring devices for monitoring it are also dispersed), the auxiliary monitoring devices are fixed in the auxiliary machine area;
云端管理平台(图中未标示，位于室内区域)，云端管理平台与轨道机器人3和辅助监测装置通信连接，云端管理平台根据预设的阈值对轨道机器人3的实时监测结果和/或辅助监测装置的实时监测结果进行比较，以进行故障预警。The cloud management platform (not shown in the figure, located in the indoor area) is communicated with the track robot 3 and the auxiliary monitoring device. The cloud management platform compares the real-time monitoring results of the track robot 3 and/or the real-time monitoring results of the auxiliary monitoring device according to a preset threshold value to provide fault warning.
具体地，针对水泥厂煤磨设备的煤磨本体2和主机设备处于室外半封闭的现场主体区域A，围绕煤磨本体2及其周边关键设备如高压润滑油站4、立磨换热站5和驱动电机6等，设计了半环形轨道，避开检修设备及人行通道，轨道机器人3采用挂轨方式与轨道1滑动连接，使得轨道机器人1根据预设的巡检任务可以在煤磨现场主体区域A内的轨道1上往复巡检。巡检任务可以根据现场磨煤机的实际工作时间定制轨道机器人3的排班巡检策略，即定时定频次巡检。每当到达指定时间，轨道机器人3自动开始执行往返巡检任务。如图2所示，为了保证巡检准确性及不妨碍人员通行，门口B位置的轨道1离地距离约为1.5米，其余位置的轨道1离地距离为2.1米。Specifically, the coal mill body 2 and the main equipment of the cement plant coal mill equipment are located in the semi-enclosed outdoor main area A. A semi-circular track is designed around the coal mill body 2 and its surrounding key equipment such as the high-pressure lubricating oil station 4, the vertical mill heat exchange station 5 and the drive motor 6, avoiding the maintenance equipment and pedestrian passages. The track robot 3 is slidably connected to the track 1 by hanging the track, so that the track robot 1 can perform reciprocating inspections on the track 1 in the main area A of the coal mill site according to the preset inspection tasks. The inspection task can customize the scheduling inspection strategy of the track robot 3 according to the actual working time of the on-site coal mill, that is, regular and frequency inspections. Whenever the specified time is reached, the track robot 3 automatically starts to perform the round-trip inspection task. As shown in Figure 2, in order to ensure the accuracy of the inspection and not hinder the passage of personnel, the track 1 at the door B position is about 1.5 meters above the ground, and the track 1 at other positions is 2.1 meters above the ground.
参见图1、3所示，本实施例中，围绕主体区域A设有若干个立柱组件8，轨道1通过立柱组件8架设，每个立柱组件8包括：As shown in FIGS. 1 and 3 , in this embodiment, a plurality of column assemblies 8 are arranged around the main area A, and the track 1 is erected through the column assemblies 8 . Each column assembly 8 includes:
底板81；Bottom plate 81;
底板81固定安装于地面，底板81上安装有支撑架82；The bottom plate 81 is fixedly installed on the ground, and a support frame 82 is installed on the bottom plate 81;
支撑架82的远离底板81的一端安装有向外延伸的横梁83；An end of the support frame 82 away from the bottom plate 81 is provided with a cross beam 83 extending outward;
横梁83的端部设有吊挂轨道1的连接件84；The end of the crossbeam 83 is provided with a connecting piece 84 for hanging the track 1;
横梁83与支撑架82的上部通过斜撑架85连接固定。The cross beam 83 is connected and fixed to the upper part of the support frame 82 via an inclined support frame 85 .
具体地，充电桩及除尘装置7安装在驱动电机6旁，通过立柱组件8固定，轨道1吊挂在立柱组件8的连接件84上。立柱组件8的支撑架82、横梁83和斜撑架85采用方钢(60×60×5mm)，底板81为0235#钢板，连接件采用角钢(90×55×6mm)，底板81通过4个M12x100膨胀螺栓固定于地面。轨道机器人3的主体轨道采用4#角钢。斜撑架85起到稳定加固整个立柱组件8的作用，防止立柱组件8倾斜，使得轨道机器人3平稳滑动于轨道1。Specifically, the charging pile and dust removal device 7 are installed next to the drive motor 6 and fixed by the column assembly 8, and the track 1 is suspended on the connector 84 of the column assembly 8. The support frame 82, beam 83 and diagonal brace 85 of the column assembly 8 are made of square steel (60×60×5mm), the bottom plate 81 is 0235# steel plate, the connector is angle steel (90×55×6mm), and the bottom plate 81 is fixed to the ground by 4 M12x100 expansion bolts. The main track of the track robot 3 uses 4# angle steel. The diagonal brace 85 plays the role of stabilizing and reinforcing the entire column assembly 8, preventing the column assembly 8 from tilting, so that the track robot 3 can slide smoothly on the track 1.
本实施例中，立柱组件8分2.1m和1.6m两种规格，2.1m的立柱组件8数量为9，1.6m的立柱组件88数量为2。In this embodiment, the column assemblies 8 are divided into two specifications of 2.1 m and 1.6 m. The number of 2.1 m column assemblies 8 is 9, and the number of 1.6 m column assemblies 88 is 2.
本实用新型的系统架构如图4所示，该系统分为三层，IAAS层：基础设施层(即感知层)，通过辅助监测装置和轨道机器人3实现现场数据的采集并传输至PAAS层；PAAS层：平台层，为应用运行提供环境支撑，主要包括数据存储处理、算法服务、运行引擎服务和报警服务。SAAS层：软件应用层，为根据本实用新型提供的煤磨设备巡检系统设计的软件应用环境。The system architecture of the utility model is shown in FIG4 . The system is divided into three layers: IAAS layer: infrastructure layer (i.e., perception layer), which collects field data through auxiliary monitoring devices and track robots 3 and transmits them to PAAS layer; PAAS layer: platform layer, which provides environmental support for application operation, mainly including data storage and processing, algorithm services, operation engine services, and alarm services. SAAS layer: software application layer, which is a software application environment designed for the coal mill equipment inspection system provided by the utility model.
轨道机器人3采用无线通讯的方式进行数据传输，巡检沿途部署无线基站实现整条巡检线路的全面覆盖。云端服务器部署在集控中心，与无线基站采用光缆通讯。巡检过程中，对沿途需要监测的仪表进行定点拍照采集，并通过无线网络传输至云端管理平台进行处理和分析。The rail robot 3 uses wireless communication to transmit data, and wireless base stations are deployed along the inspection route to achieve full coverage of the entire inspection route. The cloud server is deployed in the centralized control center and communicates with the wireless base station using optical cables. During the inspection process, fixed-point photos are taken of the instruments that need to be monitored along the way, and transmitted to the cloud management platform through the wireless network for processing and analysis.
本实用新型同时针对水泥厂煤磨设备所在的区域包括的主体区域A和辅机区域的情况，采用轨道机器人3与固定位置设置的辅助监测装置相结合的方式，在各种传感器的协作帮助下，可以检测设备的实时状态，主动监测设备故障问题，实现水泥厂煤磨设备现场的自动巡检和故障智能诊断报警，进行异常工况的识别，既减轻了巡检人员的工作强度，同时也提高了故障响应率，降低了安全风险。从而提升了巡检效率，降低了设备宕机率和设备维护成本，确保企业的安全生产。The utility model also aims at the main area A and the auxiliary area where the coal mill equipment of the cement plant is located. By combining the track robot 3 with the auxiliary monitoring device set at a fixed position, with the help of various sensors, the real-time status of the equipment can be detected, and the equipment failure problems can be actively monitored. The automatic inspection and intelligent fault diagnosis alarm of the coal mill equipment on site of the cement plant can be realized, and the abnormal working conditions can be identified, which not only reduces the work intensity of the inspection personnel, but also improves the fault response rate and reduces the safety risk. Thereby improving the inspection efficiency, reducing the equipment downtime rate and equipment maintenance cost, and ensuring the safe production of the enterprise.
参见图5所示，在一些实施例中，轨道机器人3包括：As shown in FIG5 , in some embodiments, the track robot 3 includes:
通信模块302，通信模块用于基于巡检沿途区域部署的无线基站与云端管理平台通信连接；Communication module 302, the communication module is used to communicate with the cloud management platform based on the wireless base stations deployed in the inspection area;
行走机构，行走机构用于驱动轨道机器人3沿轨道1滑动行走；A walking mechanism, which is used to drive the track robot 3 to slide along the track 1;
定位装置，定位装置用于沿轨道1固定的RFID标签对轨道机器人3进行全局定位和巡检点定位；A positioning device, the positioning device is used to perform global positioning and inspection point positioning of the track robot 3 along the RFID tags fixed along the track 1;
采集装置，采集装置用于采集煤磨本体2和主机设备的仪表数据和煤磨主电机的温度数据，上传至云端管理平台；A collection device is used to collect instrument data of the coal mill body 2 and the host equipment and temperature data of the coal mill main motor, and upload them to the cloud management platform;
供电模块，供电模块分别电连接通信模块、行走机构、定位装置和采集装置。A power supply module is electrically connected to the communication module, the walking mechanism, the positioning device and the collection device respectively.
在一些实施例中，采集装置包括：In some embodiments, the collection device includes:
双目摄像头303，双目摄像头303用于对煤磨本体2和主机设备的现场情况进行拍摄采集，以及在不同的巡检点对煤磨本体2和主机设备的多个现场仪表的仪表数据进行拍摄采集；Binocular camera 303, binocular camera 303 is used to capture and collect the on-site conditions of the coal mill body 2 and the host equipment, and to capture and collect instrument data of multiple on-site instruments of the coal mill body 2 and the host equipment at different inspection points;
红外热成像仪305，红外热成像仪305用于对煤磨设备的主电机进行温度监测。Infrared thermal imager 305, infrared thermal imager 305 is used to monitor the temperature of the main motor of the coal mill equipment.
轨道机器人3上装有双目摄像头，双目摄像头303的拍摄位置对准煤磨机。轨道机器人3在围绕煤磨机进行巡检时，利用红外热成像仪305和双目摄像头303同时进行红外温度监测和可见光监控。红外热成像仪305利用红外热成像技术监测煤磨设备主电机的温度异常，对煤磨机的关键设备进行定点红外测温，将识别结果与正常阈值比对，超出正常阈值生成故障信息，从而及时报警，避免因设备温度较高异常引发安全事故。双目摄像头303的作用主要有两个，一是用于轨道机器人巡检时对主体区域A的现场设备运行情况进行拍摄监控，并将视频传送回云端管理平台便于操作人员实时查看现场情况；二是用于对主体区域A中煤磨本体2和主机设备的多个现场仪表的仪表数据进行拍摄。轨道机器人3的定位装置配有里程计，沿轨道1固定设置的RFID标签用于全局定位，轨道机器人3巡检时通过观测读取RFID标签信息及里程系统可以快速定位巡检点，同时还可以实时校正里程计信息，并实时上传当前轨道机器人3的位置。轨道机器人3沿轨道1巡检，到达里程计设定位置时，轨道机器人3自动按照设定调整摄像头角度，对现场仪表进行拍照保存(当环境光线较暗，通过设置的补光灯304进行补充照明)，将保存的巡检图片通过通信模块(WIFI模块、3G、4G或5G)上传至云端管理平台，然后云端管理平台利用机器视觉学习算法(例如YOLO-7算法)识别巡检图片中的仪表数据(包括高压油站仪表、换热站仪表、油窗液位以及煤层厚度标尺等读数)，并将仪表数据传递至云端管理平台进行现场数据监测，同时对各仪表数据设定故障报警范围，当仪表数据出现异常时，系统自动报警从而减少人工巡检的强度，提升巡检效率并缩短了故障发现的时间，提高了处理效率，从而减少安全问题的发生，保证企业安全生产。The track robot 3 is equipped with a binocular camera, and the shooting position of the binocular camera 303 is aimed at the coal mill. When the track robot 3 conducts inspections around the coal mill, it uses the infrared thermal imager 305 and the binocular camera 303 to simultaneously perform infrared temperature monitoring and visible light monitoring. The infrared thermal imager 305 uses infrared thermal imaging technology to monitor the temperature anomaly of the main motor of the coal mill equipment, performs fixed-point infrared temperature measurement on the key equipment of the coal mill, compares the recognition result with the normal threshold, and generates fault information when the normal threshold is exceeded, so as to timely alarm and avoid safety accidents caused by abnormal high equipment temperature. The binocular camera 303 has two main functions. One is to shoot and monitor the operation of the on-site equipment in the main area A during the inspection of the track robot, and transmit the video back to the cloud management platform for the operator to view the on-site situation in real time; the other is to shoot the instrument data of multiple on-site instruments of the coal mill body 2 and the host equipment in the main area A. The positioning device of the track robot 3 is equipped with an odometer, and the RFID tags fixed along the track 1 are used for global positioning. When the track robot 3 inspects, it can quickly locate the inspection point by observing and reading the RFID tag information and the mileage system. At the same time, it can also correct the odometer information in real time and upload the current position of the track robot 3 in real time. The track robot 3 inspects along the track 1. When it reaches the set position of the odometer, the track robot 3 automatically adjusts the camera angle according to the setting, takes pictures of the on-site instruments and saves them (when the ambient light is dim, supplementary lighting is provided by the set fill light 304), and uploads the saved inspection pictures to the cloud management platform through the communication module (WIFI module, 3G, 4G or 5G). Then the cloud management platform uses machine vision learning algorithms (such as YOLO-7 algorithm) to identify the instrument data in the inspection pictures (including high-pressure oil station instruments, heat exchange station instruments, oil window liquid level, and coal seam thickness scale readings), and transmits the instrument data to the cloud management platform for on-site data monitoring. At the same time, a fault alarm range is set for each instrument data. When the instrument data is abnormal, the system automatically alarms, thereby reducing the intensity of manual inspections, improving inspection efficiency, shortening the time for fault discovery, and improving processing efficiency, thereby reducing the occurrence of safety problems and ensuring safe production of the enterprise.
故障结果可通过系统的软件页面进行展示，并可以通过配置邮箱和短信联系方式，将故障信息推送给设备相关巡检人员，同时轨道机器人3也可以设置声光报警装置(三色指示灯308和扬声器309)，根据相对应的故障信号进行声光报警通知。The fault results can be displayed through the system software page, and the fault information can be pushed to the equipment-related inspection personnel by configuring email and SMS contact methods. At the same time, the track robot 3 can also be equipped with an audible and visual alarm device (three-color indicator light 308 and speaker 309) to provide audible and visual alarm notifications according to the corresponding fault signals.
上述实现各模块功能的控制程序可根据用户的实际需求通过轨道机器人3上设置的下位机烧录接口306进行烧录，并对其烧录的程序进行更新。通过上位机调试接口307与上位机连接，实现对烧录的程序进行调试。The control program for realizing the functions of each module can be burned through the lower computer burning interface 306 provided on the track robot 3 according to the actual needs of the user, and the burned program can be updated. The upper computer debugging interface 307 is connected to the upper computer to debug the burned program.
轨道机器人3具有内置的供电模块，用于对轨道机器人3的各模块进行供电。The rail robot 3 has a built-in power supply module for supplying power to each module of the rail robot 3 .
在一些实施例中，辅助监测装置包括：In some embodiments, the auxiliary monitoring device includes:
至少一个工业摄像头设于辅机区域，用于对辅助设备的运行情况进行拍摄采集，以及对辅助设备的仪表数据进行拍摄采集；At least one industrial camera is arranged in the auxiliary equipment area, for photographing and collecting the operation status of the auxiliary equipment, and photographing and collecting the instrument data of the auxiliary equipment;
粉尘传感器，粉尘传感器设于辅机区域，用于对辅机区域的粉尘数据进行监测。Dust sensor: The dust sensor is installed in the auxiliary machine area and is used to monitor the dust data in the auxiliary machine area.
具体地，辅助监测装置主要实现两种功能：辅机区域的仪表识别和漏粉监测。通过工业摄像头监控煤仓下料区及软连接处的现场情况并将视频传送回云端管理平台便于操作人员实时查看现场情况是否正常；并利用摄像头实时监控识别压力表数据并拍照保存图片，云端管理平台利用机器视觉学习算法识别压力球表中压力球所处位置，判断风机压力情况，以便提醒设备管理人员及时调整风机的压力计；而粉尘传感器用于监测辅机区域中收尘器区域和下料仓区域是否有漏粉情况，当监测粉尘数据异常时现场有漏粉的风险，巡检人员可以调取工业摄像头的监控视频画面进行情况确认，并及时进行处理，从而避免危险的发生。Specifically, the auxiliary monitoring device mainly realizes two functions: instrument identification and powder leakage monitoring in the auxiliary machine area. The on-site conditions of the coal bunker unloading area and soft connection are monitored by industrial cameras and the video is transmitted back to the cloud management platform for operators to check whether the on-site conditions are normal in real time; the camera is used to monitor and identify the pressure gauge data in real time and take pictures to save the pictures. The cloud management platform uses machine vision learning algorithms to identify the position of the pressure ball in the pressure ball gauge and judge the fan pressure conditions, so as to remind equipment management personnel to adjust the fan pressure gauge in time; and the dust sensor is used to monitor whether there is powder leakage in the dust collector area and the unloading bin area in the auxiliary machine area. When the monitored dust data is abnormal, there is a risk of powder leakage on site. The inspection personnel can retrieve the monitoring video screen of the industrial camera to confirm the situation and deal with it in time to avoid danger.
在一些实施例中，轨道机器人3包括：In some embodiments, the track robot 3 includes:
轨道清扫毛刷301，轨道清扫毛刷301设置于轨道机器人3与轨道1的连接处。The track cleaning brush 301 is arranged at the connection between the track robot 3 and the track 1 .
具体地，轨道机器人3的顶部与轨道1交接处装有轨道清扫毛刷301，可用于清扫轨道1上的灰尘及积雪等避免机器人运行受外物阻碍，并且为了适应高纬度地区冬季室外的寒冷天气，需将毛刷的长度控制在1厘米左右，从而减少机器人爬坡时的摩擦阻力。Specifically, a track cleaning brush 301 is installed at the junction of the top of the track robot 3 and the track 1, which can be used to clean dust and snow on the track 1 to prevent the robot's operation from being hindered by external objects. In order to adapt to the cold weather outdoors in high-latitude areas in winter, the length of the brush needs to be controlled at about 1 cm, thereby reducing the friction resistance of the robot when climbing.
在一些实施例中，还包括：In some embodiments, it also includes:
至少一组充电桩和除尘装置7，充电桩和除尘装置7设置在轨道1的一侧或两侧，并与轨道机器人3的本体位置对应设置，充电桩设有定位传感器。At least one set of charging piles and dust removal devices 7, the charging piles and dust removal devices 7 are arranged on one side or both sides of the track 1, and are arranged corresponding to the main body position of the track robot 3, and the charging piles are provided with positioning sensors.
具体地，轨道机器人3实时监测当前电量情况，根据轨道机器人3的定位装置与充电桩的定位传感器之间的通信计算当前机器人位置与充电桩的距离，依据自主回充策略，自主导航至充电桩，并自动与充电桩通信启动充电。同时在充电桩附近部署除尘装置，关闭电源开关310对轨道机器人3进行充电。当轨道机器人3在充电的时候，除尘装置自动启动，对机器人的摄像头表面等位置进行除尘，保证机器人的检测效果。一般来讲，为节约成本，针对轨道机器人3设置一组的充电桩和除尘装置，可设置在轨道1的起始端附近，方便轨道机器人3完成巡检任务后与充电桩连接进入自主充电模式。Specifically, the track robot 3 monitors the current power status in real time, calculates the distance between the current robot position and the charging pile based on the communication between the positioning device of the track robot 3 and the positioning sensor of the charging pile, and autonomously navigates to the charging pile according to the autonomous recharging strategy, and automatically communicates with the charging pile to start charging. At the same time, a dust removal device is deployed near the charging pile, and the power switch 310 is turned off to charge the track robot 3. When the track robot 3 is charging, the dust removal device automatically starts to remove dust from the camera surface of the robot and other locations to ensure the detection effect of the robot. Generally speaking, in order to save costs, a group of charging piles and dust removal devices are set for the track robot 3, which can be set near the starting end of the track 1, so that the track robot 3 can connect to the charging pile and enter the autonomous charging mode after completing the inspection task.
优选地，充电桩采用无线充电结构，具有电能发射装置，轨道机器人具有与电能发射装置对应设置的电能接收装置311。Preferably, the charging pile adopts a wireless charging structure and has a power transmitting device, and the rail robot has a power receiving device 311 arranged corresponding to the power transmitting device.
优选地，除尘装置采用吹风机结构并安装固定在轨道的立柱组件上，除尘装置的出风口朝向轨道机器人的采集装置。Preferably, the dust removal device adopts a blower structure and is installed and fixed on the column assembly of the track, and the air outlet of the dust removal device faces the collection device of the track robot.
实施例二Embodiment 2
如图6所示，本实施例还提供一种应用于如上所述的煤磨设备巡检系统的巡检方法，包括如下步骤：As shown in FIG6 , this embodiment further provides an inspection method applied to the above-mentioned coal mill equipment inspection system, comprising the following steps:
步骤S1：轨道机器人根据预设的巡检任务在轨道上对煤磨本体和主机设备进行巡检，得到第一监测结果；Step S1: the track robot inspects the coal mill body and the host equipment on the track according to the preset inspection task to obtain the first monitoring result;
步骤S2：辅助监测装置对辅助设备进行监测，得到第二监测结果；Step S2: the auxiliary monitoring device monitors the auxiliary equipment to obtain a second monitoring result;
步骤S3：云端管理平台基于第一监测结果和/或第二监测结果进行数据识别处理，将识别结果与预设阈值进行比较，超出预设阈值生成故障信息并进行故障告警。Step S3: The cloud management platform performs data identification processing based on the first monitoring result and/or the second monitoring result, compares the identification result with a preset threshold, and generates fault information and issues a fault alarm if the preset threshold is exceeded.
需要说明的是，步骤S1、S2不代表先后顺序。It should be noted that steps S1 and S2 do not represent a sequential order.
具体地，本方法针对立煤磨设备半开放式的环境，利用轨道机器人进行立煤磨设备的主体区域的现场设备和仪表进行数据识别和状态监测，同时结合辅助监测装置的固定摄像头和粉尘传感器，实现辅机区域的现场巡检和监控。云端管理平台自动进行煤磨设备的现场仪表数据的识别和故障报警，实现了煤磨设备数据的精准自动采集和智能化在线监测，从而实现对设备故障的诊断，进而对煤磨机维修提供指导，减少设备故障对生产造成的影响，为设备维修由定期维修向预知性维修转变提供支撑。Specifically, this method targets the semi-open environment of vertical coal mill equipment, uses a track robot to perform data recognition and status monitoring of the on-site equipment and instruments in the main area of the vertical coal mill equipment, and combines the fixed camera and dust sensor of the auxiliary monitoring device to realize on-site inspection and monitoring of the auxiliary area. The cloud management platform automatically recognizes the on-site instrument data of the coal mill equipment and alarms for faults, realizes the accurate automatic collection and intelligent online monitoring of coal mill equipment data, thereby realizing the diagnosis of equipment faults, and then providing guidance for coal mill maintenance, reducing the impact of equipment failures on production, and providing support for the transformation of equipment maintenance from regular maintenance to predictive maintenance.
另外，由于本实施例的煤磨设备巡检方法的实现基于上述实施例所示的煤磨设备巡检系统，煤磨设备巡检系统的具体结构参照上述实施例，则本实施例所示的煤磨设备巡检方法包括了上述实施例的全部技术方案，因此，至少具有上述全部技术方案所取得的所有有益效果，在此不再一一赘述。In addition, since the implementation of the coal mill equipment inspection method of this embodiment is based on the coal mill equipment inspection system shown in the above embodiment, and the specific structure of the coal mill equipment inspection system refers to the above embodiment, the coal mill equipment inspection method shown in this embodiment includes all the technical solutions of the above embodiment, and therefore, it has at least all the beneficial effects achieved by all the above technical solutions, which will not be repeated here one by one.
最后应说明的是：以上实施例仅用以说明本实用新型的技术方案，而非对其限制；尽管参照前述实施例对本实用新型进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本实用新型各实施例技术方案的精神和范围。Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the utility model, rather than to limit it. Although the utility model has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the utility model.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202322649683.0UCN221085925U (en) | 2023-09-27 | 2023-09-27 | Inspection system of coal mill equipment |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202322649683.0UCN221085925U (en) | 2023-09-27 | 2023-09-27 | Inspection system of coal mill equipment |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202322649683.0UActiveCN221085925U (en) | 2023-09-27 | 2023-09-27 | Inspection system of coal mill equipment |
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| CN120120457A (en)* | 2025-05-08 | 2025-06-10 | 四川农业大学 | A device for biodiversity monitoring |
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