Study On Manufacturing Equipment Remote Monitoring&Fault Diagnosis System

With the rapid development of Internet/Intranet technology, modern manufacturing mode is moving towards the integration networking and globalization. The intelligent manufacturing, distributed network manufacturing and other advanced concepts come forth successively.The manufacturing equipments include the CNC machines, the PLC controlled equipments and the robots etc. These were the most basic equipment of the modern manufacturing systems. The health running of the equipments is the fundamental guarantee for the manufacturing enterprises. The technologies of equipments are developing rapidly, so the increasingly complex structure&process for these equipments make the fault diagnosis more and more important.This paper analyzed the challenge of modern equipment manufacturing system in present. With the support of the existing technologies and visible technologic trend, the remote monitoring and fault diagnosis system was studied deeply.The research starts from the system architecture and key enabling technology. The versatility of system as an important principle, paper proposed the structure and function model of the diagnosis system, raised real-time data service platform (RDSP) features model, which provided the data services to the upper integration. The real-time data acquisition, data management and service function were in-depth studied. The paper proposed diagnostic knowledge model of structure-fault tree that organize the knowledge effectively. A hierarchy integral intelligent diagnosis process was researched, which can be directed by the experience knowledge and data from RDSP real-time system. The collaborative and evaluation methods of coordination in the network diagnosis environment were also discussed. The main research works in this paper as follows:(1) Analyzed the function requirements of the fault diagnosis system in the modern manufacturing environment, proposed integration framework and functional model, and made a systematic, elaborated description, which was the foundation for forward implementation. (2) Analyzed the feature of real-time data content and acquisition interface from the production site. Analyzed the demand for real-time data services, proposed the flat structure based of RDSP. For real-time data application in WAN, the use of the hash map and Socket thread pool technology to solve real-time data services, concurrency issues, practice testified that it obtained the desired effect. RDSP research includes the platform structure, the memory maintenance of the real-time data, real-time data acquisition, historical data maintenance, data services and other specific features.(3) Analyzed the inherent characteristics of manufacturing equipment and its fault characteristics adequately, analyzed the characteristics of various practical diagnosis methods, in order to solve the singularity limitations of the existing theory, proposed structure-fault tree methods of knowledge organization. An intelligent hierarchy integral diagnosis inference model was researched. After the collection and analysis of a large number of CNC machine failure samples, the inference methods that were based on the diagnosis process and the characteristics of fault was extracted respectively. Meanwhile, in the case of knowledge is insufficient, proposed a data-oriented ANFIS inference method.In the vertical view of structure, the diagnosis implementation in field controller was explained. In the distributed collaborative environment, the basic structure of a fault diagnosis, function and evaluation was discussed. The integrated diagnostic functions make diagnosis maintenance process accurate and efficient.(4) On the basis of the above-mentioned principle, under the auspices of the Ministry of Education Doctor Foundation,"The CNC-based Intelligent Network Research"(145015) and "Remote Control Coordination Design Technology Machinery and Equipment Based on CSCW "(105057), and other practice CIMS projects, using the CNC, PLC, OPC,. NET, XML Web Service, AJAX, database technologies, developed the remote monitoring and diagnosis prototype system, that was suitable for both Web Client and WinForm Client appliances, analyzed the key technologies to system development, which has checked the feasibility and practicality of the proposed idea.