Study On Fault Monitoring And Fault Diagnosis Of Microcrystalline Phosphor Copper Ball Unit

Under the strategic planning of "made in China 2025",China’s manufacturing enterprises are facing new demands of transformation and upgrading.The new generation of information technology is applied in the industrial automation production line to accelerate the improvement of intelligence level and p roduction efficiency.This paper takes the school enterprise cooperation project as an opportunity,In order to improve the level of industrial intelligence,the transformation of phosphor copper ball unit is required.According to the demand of field condition monitoring,a set of integrated line control consisting of electrical system,mechanical system,hydraulic system,monitoring system and fault diagnosis system was proposed.A phosphor copper ball production line based on Siemens PLC is designed,and its key units are described.A workshop level monitoring and control center and remote operation and maintenance system with Win CC as the core are constructed.The causes of equipment operation faults are analyzed and the expert system based on fault tree theory is established to complete the field fault diagnosis.Based on the idea of intelligent manufacturing,this paper aims to reconstruct the hydraulic forming unit of phosphor copper ball,build workshop level monitoring platform and fault diagnosis expert system,The main work contents are as follows:First,this project take the pressure workshop of the enterprise as the research background,and take a production line of phosphor copper ball as the automatic implementation object.Based on the production control requirement of phosphor copper ball,this paper starts from the production process and analyzes the composition of the unit and the working principle of the production line,in addition,this paper studies the precise control strategy of the fixed size feed and upsetting pressuer,and puts forward the overall layout of the automatic production line,the workshop level production monitoring platform,the overall scheme of the fault diagnosis expert system.Secondly,in the aspect of automatic production line,the industrial Ethernet Fieldbus Control System Based on PLC is constructed.The distributed monitoring of C/S architecture is built through intranet.The economic S7-200 smart PLC is selected as the controller,combined with the power module,I/O module,extension module,sensor and switch constitute the control system,the distributed I/O is used to realize the digitalization and networking of the equipment,and the HMI is designed to realize the process control of the equipment parameters.On the workshop level monitoring platform,using Win CC configuration software to monitor the key parameters of the equipment in operation stage.Combined with the requirements of wo rkshop information integration,Win CC is used to configure the login interface,display interface,alarm interface,debugging interface,trend chart and other common functions.The workshop monitoring computer uses OPC client to access the OPC server through the OPC interface to monitor multiple devices on the site,receive monitoring signals in real time,find problems in the production process in time,and adjust the working state of the equipment;designs the VPN remote operation and maintenance system.Thirdly,aiming at the common fault problems in the produ ction process,an expert system based on fault tree analysis is const ructed by integrating the fault tree theory with the expert system.The fault tree model of the unqualified production quality of phosphor copper ball and the fault of the hydraulic system is emphatically listed.The knowledge base and reasoning machine of expert system are designed by CLISP,the fault tree is used as the knowledge source,and the knowledge base of expert system is written by generation rules.C++ is responsible for the design of human-computer interaction interface and the comp ilation of functional programs,the design of fault diagnosis,corrective measures,knowledge base management,user management and other major functions,using SQL SERVER as the expert system database(rule base),responsible for storing data and adding and modifying k nowledge base.The failure components are determined with the operation parameters of the equipment as the symptoms,through effective reasoning,the failure causes can be obtained.Therefore,it is of great significance for the whole production system to ensure the safety of the production line.