A Cement Production Equipment's Off-Line Detection And Fault Diagnosis System Based On PDA

The key equipment in cement production has characteristics of large size, complex structures, high automation, difficulty of maintenance. Once malfunction occurs, huge economic losses will be caused. Therefore, it's important to detect the running state of the equipment for finding anomalies in real time, and then achieving the early prevention and diagnosis of equipment faults. On the other hand, the fixed point inspection of equipment which is an off-line detection method is an important means for ensuring the stable operation of cement equipment. Under the background of a research project of"Monitoring and fault diagnosis technology of key components of NSP cement production line", a cement poduction's off-line detection and fault diagnosis system based on PDA was studied in this paper, and a portable condition detector and signal analyzer was put forward, which is helpful for improving the detection level of inspection staff, and easy for comprehensive and timely detection of equipment conditions.The research development situation and trend of the equipment monitoring and fault diagnosing technology and related system were summarized in this paper. And then, the problems and current situation of equipment state detection and fault diagnosis in cement equipment,and the necessity and significance of establishing a condition detection and fault diagnosis system for cement equipment were analyzed.Based on analyzing the key equipment and processes in cement production and the needs of cement enterprises for the monitoring and diagnosing system, the general frame and architecture of the detecting and fault diagnosing system was researched in this paper. Then, the functions of system components and the process of detecting equipment state and diagnosing fault in this system were analyzed.The structure and common faults types of a key equipment in cement production that was the reducer of rotary kiln were introduced in this paper. And, the methods for detecting the reducer state, the time-filed analysis, the amplitude-filed analysis and the trend analysis, were introduced. Moreover, the methods for diagnosing the faults of reducer, the frequency spectrum analysis and the diagnosis based on CBR, were analyzed.Based on completing the design of system structure and functions, the problems of hardware selection and software development were studied in this paper. The SCM STC89C52 was selected for controlling accelerometers ADXL210 to collect vibration signal and temperature sensor DS18B20 to collect temperature signal, and the HP iPAQ H3970 was selected for data storage and analysis. Then, the database management tool SQL Server CE used in PDA was selected to manage the system's data, and the optimization design of database was carried out. A modularized procedure designing method was adopted in this software, including the data collecting module, diagram displaying module, communication module which consisted of the communication module, state analysis module, fault diagnosis module and data management module.