基于WirelessHART的泵群无线状态监测

发布时间：2018-01-22 23:46

本文关键词： 工业无线网络 WirelessHART网关 WirelessHART传感器 WirelessHART网络管理　出处：《华南理工大学》2013年硕士论文　论文类型：学位论文

【摘要】：在化工企业，维持正常的生产和增效益必须要靠设备的可靠性和先进的维修模式来支持。泵作为生产环节中的关键设备，传统的监测方法是靠定期的人工巡检和手摸耳听来判断泵和轴承的运行状态。这种传统的泵的监测方式，需要消耗大量的人力成本，最大的风险还在于因每个人对泵的理解和经验上的差异，导致对泵的潜在故障的评判上存在差异或误判，不能从根本上消除泵的设备故障。上世纪80年代在化工企业推行的在线监测系统，在泵体轴承座位置安装在线传感器，现场敷设信号线和通信电缆，将传感器采集的振动信号引入到安装在现场的监测单元。通过分析采集的振动信号，可以定性的评判设备的故障类型，轴承损伤部位和严重程度。这种先进的在线监测方式，改变了工厂的维修策略，将设备维修模式从失效性维修推向了预测性维修。整个设备的维修费用得到了大幅的降低。但由于化工环境下的防爆需要，这种在现场敷设信号线和电缆，安装传感器和监测单元，导致施工周期长、材料成本高、人力成本贵和后期的维护成本高。由于现代通信技术和微电子技术的快速发展，通过在泵区搭建无线监测系统，可实现在生产现场无需敷设任何信号电缆线和通信电缆。整个无线监测系统搭建快速，实现的周期极短。相比在线监测系统，无线监测系统的安装、调试和后期维护的成本极低，并且系统可实现在线系统同样的监测功能。 WirelessHART (Wireless Highway Addressable Remote Transducer-无线高速可寻址远程传感器)监测系统具备监测设备的振动值（mm/s），加速度包络值(mm/s^2)，温度值(oC)和电池的电量。通过设定的数据采集时间和周期，系统将通过传感器轮询和网关轮询的两种模式将监测数据，通过无线网络将采集的数据传输到主机。作为在国内首次采用WirelessHART监测系统来监测泵的状态，，无任何案例和实施经验参照的情况下，结合在现场的项目实施所累计的应用经验，本论文的主要研究工作是：1）如何选择安装WirelessHART网关和网络适配器的位置，来搭建运行可靠，无线信号覆盖广的WirelessHART网络监测系统；2）如何选择安装WirelessHART传感器的位置和天线的朝向来保证采集的振动信号有效，以及无线传感器的信号能前后覆盖；3）如何设定数据的采集模式、数据的采集时间、数据采集的循环周期和传感器的节点模式来保证整个无线监测系统的健壮性，以及传感器获得更长的使用寿命；4）如何通过分析网络日志文件来分析网络系统和无线节点的可靠性；5）如何通过解读采集的数据，结合一个轴承外圈早期损伤的案例来确认采集的数据的有效性；6）提出系统还需要改进的地方。
[Abstract]:In chemical enterprises, the maintenance of normal production and efficiency must rely on the reliability of equipment and advanced maintenance mode to support. Pump as the key equipment in the production process. The traditional monitoring method is to judge the operating state of the pump and bearing by the regular manual inspection and the hand touching ear. This traditional monitoring method of the pump needs to consume a large amount of manpower cost. The biggest risk lies in the difference of understanding and experience of the pump, which leads to the difference or misjudgment of the potential fault of the pump, which can not fundamentally eliminate the equipment fault of the pump. In -20s, the on-line monitoring system was implemented in chemical enterprises. The on-line sensor was installed in the position of the bearing seat of the pump body, and the signal lines and communication cables were laid on the spot. The vibration signal collected by the sensor is introduced into the monitoring unit installed in the field. By analyzing the vibration signal collected, the fault type of the equipment can be judged qualitatively. Bearing damage location and severity. This advanced online monitoring method has changed the maintenance strategy of the factory. The maintenance mode of the equipment has been pushed from failure maintenance to predictive maintenance. The maintenance cost of the whole equipment has been greatly reduced. However, due to the need of explosion proof in chemical environment, the signal lines and cables are laid in the field. Installation of sensors and monitoring units leads to long construction cycle, high cost of materials, high cost of manpower and high cost of later maintenance. Due to the rapid development of modern communication technology and microelectronics technology, wireless monitoring system is built in the pump area. The wireless monitoring system can be constructed quickly and the period of realization is very short. Compared with the on-line monitoring system, the wireless monitoring system can be installed. The cost of debugging and later maintenance is very low, and the system can achieve the same monitoring function as online system. WirelessHART (. Wireless Highway Addressable Remote Transducer-Wireless High-Speed addressable remote Sensor. The monitoring system has the vibration value of the monitoring equipment (mm / s). The acceleration envelope value of m / m / s ^ 2, the temperature value of C) and the battery's electricity quantity. By setting the time and period of data acquisition, the system will monitor the data through the two modes of sensor polling and gateway polling. The collected data is transmitted to the host through the wireless network. As the first time in China to use the WirelessHART monitoring system to monitor the status of the pump, without any case and implementation experience reference, combined with the site of the project implementation of the cumulative application experience. The main research work of this thesis is how to choose the location of installing WirelessHART gateway and network adapter to build up and run reliably. Wireless signal coverage of the WirelessHART network monitoring system; 2) how to select the position of the WirelessHART sensor and the orientation of the antenna to ensure that the collected vibration signal is effective, and the signal of the wireless sensor can cover the front and back; 3) how to set the data acquisition mode, the time of data acquisition, the cycle period of data acquisition and the node mode of sensor to ensure the robustness of the whole wireless monitoring system. And the sensor to obtain a longer service life; 4) how to analyze the reliability of network system and wireless nodes by analyzing network log files; 5) how to confirm the validity of the collected data by interpreting the collected data and combining with a case of early damage to the outer ring of bearing; 6) the system needs to be improved.
【学位授予单位】：华南理工大学
【学位级别】：硕士
【学位授予年份】：2013
【分类号】：TH38;TP274

【参考文献】