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Summary
This article comes from the Gizwits developer taking the crusher, an important component of the feed unit, as the research object. Based on the full investigation of the feed production plant, he designed a real-time fault detection system for the crusher based on the Gizwits platform. The main components of the system are the fault diagnosis terminal, the Internet of Things platform , the upper computer software and the smartphone APP, etc.
The fault detection terminal uses STM32 F103VET6 as the main control chip, combined with sensor components and esp8266 chip, to realize the detection and transmission of electrical signals, vibration signals, temperature and humidity signals generated during the operation of the shredder.
The cloud is based on the Gizwits cloud server, combined with the fault detection terminal, and builds the Gizwits cloud server for the types of shredder failures. Based on the cloud communication protocol, it realizes the information interaction between the Gizwits cloud and the fault detection terminal. The upper computer interface adopts the joint programming of Lab VIEW and C language, which not only deploys and develops the visual interface, but also uses C language to transplant the wavelet algorithm to realize the analysis and diagnosis of the fault cause. The development of the mobile phone APP is based on Android Studio software and combined with Gizwits Cloud, to design and develop a mobile phone application software that can interact with the cloud monitoring platform of the shredder fault detection system. This software can be implemented with the fault detection terminal through WiF i Information interaction and control.
The design of the remote fault detection system for the shredder based on the Gizwits IoT platform combines cloud platform technology, embedded technology, mobile APP design technology and fault detection technology. Compared with the existing fault detection technology, it has significant technical advantages , And has strong practicability.
Keywords: pulverizer; fault detection; embedded; IoT platform; wavelet algorithm; host computer; APP
grinder
Based on the working characteristics and working environment of the shredder, this paper designs a remote fault detection system for the shredder based on the Gizwits IoT platform to realize the design of the remote fault detection and detection system for the shredder to realize the remote fault detection of the shredder Cloud platform technology integrates diagnostic data, diagnostic systems, diagnostic objects, and monitoring facilities through a network to realize real-time monitoring and remote fault monitoring of the shredder.
It can realize the automatic acquisition of fault information, intelligent information management and information integration, and realize the real-time monitoring of operating equipment, obtain real-time information of the equipment, send out alarm signals in time for the monitored problems, notify the maintenance personnel to deal with it, so that the equipment can be operated In good operating condition.
A complete cloud platform system including various sensors and Gizwits cloud platform servers. The in-depth integration and mutual penetration of fault diagnosis technology and cloud platform technology makes the grinder and basic communication equipment better integrate, realizes the effective use of resources, and the automation, information and intelligence of the feed unit can be better To ensure the production of feed. Therefore, it has important practical significance to carry out the research of fault diagnosis system based on the cloud platform.
1. Hardware requirements:
1.
Accurate signal detection. The sensor is required to detect vibration, current, temperature and humidity signals during the operation of the shredder, and the sensor can work stably under complex working conditions. 2. Fast and accurate signal processing. The control chip is required to be able to process the detected signals in a timely and accurate manner, and directly make judgments and alarms for failures such as power failure and blockage. 3. Stable operating environment. The fault detection terminal needs to be installed on the production line site, so stability is the basic requirement for the system, and the fault detection terminal requires that it can work stably for a long time under the conditions of dust and noise.
2. Software requirements:
1.
Independent upper computer software. It is required that the pulverizer fault diagnostic device can be directly connected to the upper computer using a serial port or RS485, and the equipment operation information is imported into the upper computer configuration software. The main functions of the software require such functions as parameter configuration, monitoring data storage, temperature and humidity dynamic curve display, control signal transmission and fault alarm.
2.
Gizwits IoT Platform:
The remote PC client is required to log in to the Gizwits IoT platform without the upper computer software to view the running status of the shredder in real time. The platform is required to have good reliability, security, and real-time.
3.
The mobile phone client associated with the Internet of Things platform. It is required that even when there is no PC beside the customer, the operating status of the shredder can still be understood through the mobile client associated with the smart cloud platform. The client is required to have good operating efficiency and the response time is less than 2 seconds.
Third, the overall architecture of the crusher fault detection system
根据粉碎机远程故障检测系统功能需求，可以将故障检测系统分为三部分，分别为由传感器和故障诊断器组成的故障检测终端，由上位机和手机 APP 组成的客户终端，由无线网络和机智云服务器组成的机智云终端。用户在客户终端通过因特网向故障诊断器发出请求，故障诊断器在接收到请求之后向传感器发送信号采集命令，传感器接收到命令之后开始对制粒机进行信号采集。采集到的数据经传感器传输到故障诊断器，由无线网络发送到服务器中，再经过因特网传输到相应的客户端，具体如图 2.1 所示。
四，云平台选择
我选择了机智云物联网平台完成故障检测系统的搭建。机智云是领先的物联网开发和云服务平台，AIoT全栈（综合）物联网平台服务领先者，工业互联网平台优秀技术供应商，在物联网、云计算、大数据和人工智能等新一代信息技术领域拥有丰富的产品和实施经验，目前已服务全球200+国家/地区，业务覆盖交通物流、新能源、工业互联、医疗健康、消费电子等众多行业，在国内多个行业实现市场覆盖率领先。详情至www.gizwits.com了解更多或咨询在线客服。
首先对粉碎机故障检测系统进行需求分析，并根据功能需求设计总体方案。根据系统需求选取 STM32F103VET6 微控制器芯片作为核心控制芯片，针对故障种类，选用DHT11 数字温湿度传感器来检测饲料的温度和湿度，选用 LSMZJ1-0.5 电流互感器作为粉碎机故障检测系统的电信号传感器，选用压电振动敲击传感器检测粉碎机在运行过程中产生的振动信号。对故障诊断器的通信方式进行了阐述，选用 WIFI 无线通讯方式将故障诊断终端接入互联网，选取RS485串口将故障检测终端检测的传感器信号传输给上位机。对云平台进行了阐述，选取机智云物联网平台来完成故障检测系统的搭建。
五，配置入网
使用 GAgent 固件将故障检测终端接入机智云需要经过三个步骤， 1、设备上电连接。这时 GAgent 向设备端发送请求，设备端接收到请求之后向运行GAgent 固件回复设备信息，如果设备正常工作，那么就将回复 GAgent 所发射出去的心跳包，心跳包 55S 一次，超出三次未回应则连接失败。 2、配置入网。借助 ESP8266 接收通过 UPD 广播方式传送而来的局域网账号和密码，进而连接局域网，实现与机智云的通信。
设备的绑定。故障检测终端在实现与机智云的通信之后发送绑定命令。
六，设备接入机智云物联网平台方案
在本文中主要使用了机智云的WIFI接入方式，如图 5.7 所示，故障检测终端通过 WIFI 连接云平台实现故障信息的远程监控。
七，机智云开发流程
接入机智云物联网平台首先要进行
账户的注册
，然后创建产品，再对设备和应用进行调试。确定产品可以满足目标需求之后，可以向机智云官方提出发布请求，机智云公司会在云端为产品提供独立的运行环境，具体的接入流程如图 5.8 所示
八，机智云云端服务器的搭建
登陆注册账号，进入开发者中心，点击创建新产品按钮，进入产品创建界面，开始粉碎机故障检测仪机智云终端的创建，具体操作如：
图 5.12所示。检测仪机智云终端的创建
数据点的创建
创建数据点是产品创建过程中非常重要的一环，数据点的主要作用是描述粉碎机故障检测终端所主要检测的对象以及参数，是粉碎机故障检测终端功能的抽象描述。如图5.13 所示在数据点创建之后，终端设备便可以与机智云网络相互发送数据。
图 5.13 数据点功能概述
为了在最大程度上满足机智云设备对于流量和资源的要求，机智云物联网平台的数据节点对传输的数据类型做出了详细的划分，具体结构如图 5.14 所示。并且使用一个字节来表示机智云数据节点的最小功能单位，以降低流量消耗。
九，产品发布
产品的发布在机智云的云端服务器搭建成功后，用户只需将设备数据接入云平台进行相关测试，机智云物联网平台为开发者提供了完整的运行测试环境，代码自动生成等等。如果产品开发成功可以向机智云提出申请，进行产品的发布。
在产品发布完成后，设备监控平台会运行在正式的服务器上，并拥有独立的云端运行环境，使设备可以24小时在线使用。在发布前，设备只能运行在测试服务器， API 每天最多调用 500 次，只适用于产品的调试阶段。发布后，设备运行在正式服务器，拥有独立的云端运行环境，设备连接不受限制，并且机智云官方会主动提供与其他产品合作的机会，具体如图 5.16 所示。
十，搭建Android开发平台
使用机智云物联网平台的应用开发功能，生成安卓平台代码，云平台自动生成的代码只是一个框架，使用该框架，APP可以准确的连接机智云云平台。并且在这个框架的基础上，开发者可以进行设置和扩展APP 具体功能。
十一，APP控制界面
粉碎机远程故障检测系统 APP 的控制界面的主要功能是展示粉碎机的实时运行状况，并且具有控制设备运行功能。在控制界面中，用户可以直观的观察到粉碎机运行时温度、湿度以及电流的大小。当温度、湿度或者电流信号大小超出规定范围之内，控制界面会根据相应信息判断故障种类，并对该故障进行精确报警。用户也可以通过点击报警模块，控制故障检测终端发出刺耳的警报声，从而提醒现场工作人员粉碎机出现故障。
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