基于工业互联网的钢管产线关键设备健康管理

Health management of key equipment in steel pipe production line based on industrial Internet of Things

针对钢管产线设备管理中的薄弱环节,提出了基于工业互联网的钢管产线关键设备健康管理体系架构,通过关键设备在线状态监测诊断、控制系统工艺参数、生产现场视频、现场点检、离线检测的整体融合,推进设备管理由事后维修、计划维修向预测性维护迈进,实现数字设备智能运维。结果表明:通过设备故障预测及预测性维护,平均为每条钢管生产线在6个月内减少非计划停机时间近96 h,对于关键设备的故障漏报率为0,误报率低于5%,有效降低了点检人员的工作量,设备故障停机率降低18%,生产作业率提高15%。应用应力波分析技术对穿孔机、连轧机等关键机械设备实施状态监测,利用现场丰富的生产数据,建立了设备健康状态在线监测诊断模型,对设备在多种工况下表现出的故障特征信息进行综合分析,通过数据异常报警、故障诊断及预测性维护,实现了钢管生产线关键设备故障预测及健康管理。

Aiming at the weak links in the equipment management of steel pipe production line, health management system architecture of key equipment of steel pipe production line based on industrial Internet of Things was proposed. Through the overall integration of online status monitoring and diagnosis of key equipment, control of system process parameters, production site video, on-site spot check and offline inspection, which could promote equipment management from planned maintenance to forecast maintenance, digital equipment intelligent operation and maintenance was realized. The results show that the average unplanned downtime of each production line was reduced by nearly 96 h within 6 months through equipment fault prediction and predictive maintenance, the alarm failure rate was 0 and the false alarm rate was lower than 5% for key equipment, which effectively reduces workload of spot inspection personnel, the equipment failure and shutdown rate was reduced by 18% and the production operation rate was increased by 15%. Stresswave analysis technology was applied to status monitoring of key equipment such as piercer mill, tandem mill and so on. Based on the abundant production data on site, online monitoring and diagnosis model of equipment health status was established, and fault characteristic information of equipment was comprehensively analyzed under various working conditions. Through abnormal data alarm, fault diagnosis and predictive maintenance, failure prediction and health management of key equipment in steel pipe production line were realized.