What Are Remote Diagnostics?

With the development of computer network technology, modern control technology, and sensor technology, remote fault diagnosis and maintenance technology can mobilize fault diagnosis and maintenance resources in a short time to achieve rapid, timely, and correct diagnosis and maintenance of complex systems.

With the continuous development of computer technology, communication technology and fault diagnosis technology, the demand for equipment fault diagnosis continues to increase, which has resulted in a device fault diagnosis method based on the combination of these technologies. ^[1]

The structure of modern manufacturing equipment is becoming more and more complex, and the degree of automation is getting higher and higher. Many equipments integrate mechanical, electronic,

Remote diagnosis technology is a frontier topic at home and abroad, and active research has been carried out at home and abroad. In January 1997, the first

The biggest feature of remote fault diagnosis is the geographical separation of equipment and diagnostic resources. The diagnostic resources that provide services and the diagnosed equipment communicate through the network to form a relatively loose logical whole. This allows remote resources to provide equipment with fault diagnosis services. The form has some new features. On the one hand, the diagnosis task can be decomposed into sub-problems in different fault domains, and then different remote diagnosis resources are used for diagnosis, and then all these diagnosis conclusions are synthesized, which will undoubtedly obtain a more accurate diagnosis result. Diagnostic services will be available for multiple devices in multiple locations.

Therefore, the open remote fault diagnosis system has the following characteristics: Multi-resource cooperation. There can be multiple diagnostic resources in the diagnostic system to jointly perform fault diagnosis for one device. Multi-device adaptability. It can quickly reconstruct the corresponding diagnosis system that meets the actual needs, and it is more convenient to provide fault diagnosis services for different types of equipment in different regions.

On the one hand, the remote fault diagnosis system will call the corresponding device communication interface to interact with the device according to the specific service requesting device, monitor the operating device to obtain its fault symptoms, and feedback the diagnosis result to the device, that is, through the adaptation of the device communication interface Achieve multi-device adaptability. On the other hand, the diagnostic system can call multiple different remote resources to jointly provide services for the device through the resource communication interface according to the type of the acquired zither symptoms, and coordinate the relationship between the resources, that is, to achieve multi-resources by scheduling the diagnostic resources cooperation. ^[2]

The equipment remote monitoring and diagnosis maintenance system consists of 6 parts: dynamic data acquisition unit, real-time status monitoring unit, local fault diagnosis unit, remote diagnosis expert system, remote expert consultation center and computer communication network.

Data acquisition unit

The data acquisition unit mainly completes the equipment for steady-state and dynamic data collection. In the equipment remote fault diagnosis system, the equipment must be online. Real-time monitoring and online adjustment must be supported by the field equipment data acquisition module.

2. Remote Expert Consultation Center

The main function of the remote expert consultation center is to provide the necessary collaborative working environment for equipment experts to achieve remote diagnosis, including remote monitoring, online operation support and information services.

As long as remote monitoring refers to online operation status and fault information of the field equipment, such as the output of the data acquisition unit and monitoring unit, the equipment operation status and self-diagnostic information displayed on the field control terminal, as well as CNC programs and other various control programs, etc. . Remote control mainly means that the equipment expert directly obtains the equipment control right through the network, so as to remotely operate and debug the field equipment online through the virtual operation panel. Information service mainly refers to online communication between equipment experts, experts and field staff through methods such as teleconferences, shared whiteboards and online images and sound transmission, so as to jointly analyze, diagnose, and troubleshoot.

Computer communication networks, network data transmission modules, remote monitoring and diagnosis must be carried out remotely and must be implemented through the network. The data transmission module is a web service program developed using multimedia information integration technology. Its basic function is to package the data collected by the data acquisition device in a certain format and send it to the corresponding remote diagnostic service program. At the same time, the network data transmission module is responsible for Dynamically extract and diagnose information needed by service programs and other applications, such as pressure, location, and more.

3. Intelligent maintenance becomes the development direction of remote monitoring and diagnostic equipment

In the field of traditional remote monitoring and diagnosis, most of the technology development and application are focused on signal and data processing, intelligent algorithm research (artificial neural networks, genetic algorithms, etc.) and remote monitoring technology (data transmission is not noted). The intelligent maintenance technology based on the concept of active maintenance mode focuses on the technology development and application of information analysis, performance degradation process prediction, maintenance optimization, and on-demand monitoring (mainly information transmission). The maintenance of products and equipment reflects preventiveness. Requirements in order to achieve near-zero failure and self-maintenance.

At present, due to the industry's demand for preventive maintenance technology, the research focus in the field of fault diagnosis has gradually shifted to the fields of condition monitoring, preventive maintenance and early diagnosis of failures, which has laid a solid foundation for the realization of intelligent maintenance technology. In fact, the current fault diagnosis research has reached the initial stage of the intelligent maintenance field.

The remote diagnosis and diagnosis and maintenance technology through the network have affected and penetrated into the field of sensors, so network-based sensors have emerged based on network technology. It integrates the network interface chip with the smart sensor, and solidifies the communication protocol into the ROM of the smart sensor. Network sensors have inherited all the functions of intelligent sensors and can communicate with computer networks. As a result, they have been widely used in fieldbus control systems and become field-level digital sensors. The development and application of network sensors has been promoted in turn. Development and improvement of remote monitoring and diagnostic maintenance technology. ^[2]

The traditional intelligent fault diagnosis methods are

Application of Remote Diagnosis Expert System in Harbin Electric Machine Factory Diagnosis Center Platform

The system is targeted at hydroelectric units, and consists of sensor components, signal acquisition and pre-processing units, status data servers, web servers, network systems, monitoring analysis and diagnostic software, etc., which can control vibration, displacement, temperature, and pressure of various parts of the unit. , Air gap, magnetic field strength and other parameters for real-time monitoring. It is based on rotor-bearing system dynamics, hydraulic vibration mechanism, artificial intelligence principles, as well as knowledge in various fields of operation, repair, management experience, unit design structure and manufacturing process, especially the practical experience of domain experts. A state-of-the-art monitoring and evaluation, feature extraction and signal analysis, and fault cause confirmation developed a set of application systems for the purpose of regular maintenance management of equipment to provide a basis for decision-making. For the purpose of condition evaluation, its monitoring parameters are many, its content is rich, and a large number of system analysis functions are added. Its diagnostic function provides powerful and convenient assistance for equipment maintenance.

The database server is the core of the remote diagnosis center. The other components are arranged around the server. The on-site monitoring system transmits data to the data server, and various monitoring workstations obtain the displayed and analyzed data from the data server. The database server is configured with a large-capacity disk subsystem and stores long-term historical data. Generally, 10,000 monitoring channels (of which 5000 vibration channels and 5000 process volume channels) need 1TB of storage to store data for one year. The database disk subsystem can be expanded at any time. The expansion methods are: (a) adding disk capacity to an existing server; (b) adding a new server to run in parallel with the original server. The database server is connected to the Internet network and configured with a large bandwidth.

In order to process a large amount of data, the database server should also be configured with a high-performance CPU and large-capacity memory, at least I am hungry for Xeon 3.0GHz and 2GB memory.

The users of the remote diagnosis center can be divided into diagnosis center management and monitoring and analysis users, group company management users, corporate users, collaboration unit users, and mobile users according to different places of use; according to different permissions and functions, they can be divided into systems Management, operation management, diagnostic experts, monitoring and analysis, guests, etc.

The system management workstation is located in a special place of the remote diagnosis center management department and receives a dedicated workstation under strict management. The system management software is installed on the management workstation, which can monitor, adjust and control the operating status of the entire system.

The remote fault diagnosis of equipment is a kind of equipment fault diagnosis method combining computer science, communication technology and fault diagnosis technology. The combination of equipment fault diagnosis technology and the Internet, using an open architecture, effectively solves the problems existing in traditional fault diagnosis and maintenance, improves the accuracy and timeliness of diagnosis, and significantly reduces the after-sales service costs of equipment manufacturers. It greatly improves unnecessary economic losses caused by equipment failure and maintenance caused by equipment users, and has strong vitality and broad application prospects. ^[2]