CN-122008691-A - Fault early warning method and system for advertisement printing equipment

CN122008691ACN 122008691 ACN122008691 ACN 122008691ACN-122008691-A

Abstract

The invention discloses a fault early warning method and a fault early warning system for advertisement printing equipment, which relate to the technical field of automatic control and comprise the steps of obtaining control instruction variable quantity and feedback deviation variable quantity of the advertisement printing equipment, calculating available control margin standard, calculating current control output regulating quantity to serve as instantaneous control margin consumption quantity by using the control instruction variable quantity and the feedback deviation variable quantity, selectively accumulating the instantaneous control margin consumption quantity by using a gating health memory mechanism to obtain health indexes, calculating the evolution rate of the health state of the equipment by using the health indexes, and calculating available health time windows of the advertisement printing equipment.

Inventors

HE WUJUN
HE MIN
LUO YANG
MA DANDAN
ZHANG ZHEMIN

Assignees

森凡科技有限公司

Dates

Publication Date: 20260512
Application Date: 20260310

Claims (10)

1. A fault early warning method of advertisement printing equipment is characterized by comprising the steps of, Acquiring a control instruction variable quantity and a feedback deviation variable quantity of the advertisement printing equipment, calculating an available control margin standard, and calculating a current control output regulating quantity as an instantaneous control margin consumption quantity by using the control instruction variable quantity and the feedback deviation variable quantity; Selectively accumulating the consumption of the instantaneous control margin by using a gating health memory mechanism to obtain a health index; Calculating the evolution rate of the health state of the equipment by using the health index, and calculating the available health time window of the advertisement printing equipment; And dividing the advertisement printing equipment into any health grade of normal, concerned, early-warning and critical according to the available health time window, and generating corresponding fault early-warning information and corresponding operation management measures according to the health grade.
2. The method for warning against faults of advertisement printing equipment according to claim 1, wherein the calculating of the available control margin standard comprises the following specific steps: superposing the control instruction variable quantity and the feedback deviation variable quantity according to a discrete increment control law to obtain a control output regulating quantity; a limit adjustment margin is set based on the historical control output adjustment amount, and an available control margin reference is calculated using the control output adjustment amount and the limit adjustment margin.
3. The method for warning the failure of advertisement printing equipment according to claim 2, wherein the control command variable quantity and the feedback deviation variable quantity are overlapped according to a discrete increment control law, and the method comprises the following specific steps: Determining a proportional coefficient, an integral coefficient and a differential coefficient based on the historical feedback deviation variation; The control output adjustment amount is calculated using the proportional coefficient, the integral coefficient, the differential coefficient, the control instruction change amount, and the feedback deviation change amount.
4. The method for warning against faults of advertisement printing equipment according to claim 1, wherein the selective accumulation of consumption of instantaneous control margin by using a gating health memory mechanism comprises the following specific steps: Collecting the running speed and the tension set value of the advertisement printing equipment, wherein the difference between adjacent running speeds is used as the running speed variation, and the difference between adjacent tension set values is used as the tension variation; setting a speed threshold and a tension threshold based on the historical operating speed variation and the historical tension variation; when the running speed variation does not exceed the speed threshold value and the tension variation does not exceed the tension threshold value, judging that the working condition is stable; arranging the consumption of the instantaneous control margin according to time sequence, and judging the time evolution characteristic of the consumption of the instantaneous control margin; When the working condition is stable, the gating health memory mechanism screens and accumulates the consumption of the instantaneous control margin according to the time evolution characteristic to obtain the health index.
5. The method for warning against faults of advertisement printing equipment according to claim 4, wherein the judging of the time evolution characteristic of the consumption of the instantaneous control margin comprises the following specific steps: Taking the difference between each instantaneous control margin consumption and the instantaneous control margin consumption at the previous moment as a control margin consumption variation; when the control margin consumption variation amounts are all non-negative values in a preset time window, judging that the time evolution characteristic is a continuous evolution characteristic; And when the control margin consumption variation is not fully non-negative in a preset time window, judging that the time evolution characteristic is a short-time fluctuation characteristic.
6. The method for warning against faults of advertisement printing equipment according to claim 4, wherein the health index is obtained by accumulating consumption of instantaneous control margin corresponding to continuous evolution characteristics to obtain degradation accumulation and mapping the degradation accumulation.
7. The method for warning faults of advertisement printing equipment according to claim 1, wherein the step of calculating the evolution rate of the health state of the equipment by using the health index is to calculate the difference value between the health index at the previous moment and the health index at the current moment to obtain the change amplitude of the health index, and the ratio of the change amplitude of the health index to the health index at the previous moment is taken as the evolution rate.
8. The method for warning the failure of advertisement printing equipment according to claim 1, wherein the calculating the available health time window of the advertisement printing equipment is to set a health critical index based on the historical health index, and the difference between the health index at the current time and the health critical index is used as a health allowance, and the ratio of the health allowance to the evolution rate is used as the available health time window.
9. The method for warning against faults of advertisement printing equipment according to claim 1, wherein the advertisement printing equipment is classified into any health level of normal, attention, warning and critical according to the available health time window, and the method comprises the following specific steps: setting a focus threshold, an early warning threshold and a critical threshold based on a historical available health time window; when the available health time window exceeds the attention threshold value, judging that the health grade of the advertisement printing equipment is normal; when the available health time window exceeds the early warning threshold and does not exceed the attention threshold, judging that the health grade of the advertisement printing equipment is attention; when the available health time window exceeds a critical threshold value and does not exceed an early warning threshold value, judging that the health grade of the advertisement printing equipment is early warning; and when the available health time window does not exceed the critical threshold, determining that the health grade of the advertisement printing equipment is critical.
10. A fault early warning system of advertisement printing equipment based on the fault early warning method of the advertisement printing equipment as set forth in any one of claims 1 to 9 is characterized by comprising, The evaluation module is used for acquiring the control instruction variable quantity and the feedback deviation variable quantity of the advertisement printing equipment, calculating an available control margin standard, and calculating the current control output regulating quantity as the instantaneous control margin consumption quantity by using the control instruction variable quantity and the feedback deviation variable quantity; The accumulation module selectively accumulates the consumption of the instantaneous control margin by using a gating health memory mechanism to obtain a health index; The calculating module calculates the evolution rate of the health state of the equipment by using the health index and calculates the available health time window of the advertisement printing equipment; The early warning module divides the advertisement printing equipment into any health grade of normal, concerned, early warning and critical according to the available health time window, and generates corresponding fault early warning information and corresponding operation management measures according to the health grade.

Description

Fault early warning method and system for advertisement printing equipment Technical Field The invention relates to the technical field of automatic control, in particular to a fault early warning method and system of advertisement printing equipment. Background Under the promotion of roll-to-roll continuous production, tension closed-loop control and high-speed synchronous driving technology, the advertisement printing equipment gradually forms a control system which takes a motion controller as a core and cooperates with a tension sensor and an actuating mechanism. In the current stage of engineering, discrete control laws such as incremental PID and the like are adopted to regulate the control instruction change and the feedback deviation, and the process parameters such as limit regulating allowance, alarm threshold, running speed, tension setting and the like are combined to realize the on-line monitoring and protection of tension stability and printing quality. The prior art still has the improvement that firstly, the prior fault early warning is difficult to characterize the continuous consumption rule of the control margin along with the degradation process, so that the degradation of the control margin is difficult to quantify, and secondly, the prior method lacks an interpretable calculation mechanism for the degradation evolution rate and the available running time, so that the available health time window is difficult to predict. Disclosure of Invention The present invention has been made in view of the above-described problems occurring in the prior art. Therefore, the invention provides a fault early warning method of advertisement printing equipment, which solves the problems that the degradation of control margin is difficult to quantify and the available health time window is difficult to predict. In order to solve the technical problems, the invention provides the following technical scheme: In a first aspect, the present invention provides a fault pre-warning method for an advertisement printing apparatus, comprising, Acquiring a control instruction variable quantity and a feedback deviation variable quantity of the advertisement printing equipment, calculating an available control margin standard, and calculating a current control output regulating quantity as an instantaneous control margin consumption quantity by using the control instruction variable quantity and the feedback deviation variable quantity; Selectively accumulating the consumption of the instantaneous control margin by using a gating health memory mechanism to obtain a health index; Calculating the evolution rate of the health state of the equipment by using the health index, and calculating the available health time window of the advertisement printing equipment; And dividing the advertisement printing equipment into any health grade of normal, concerned, early-warning and critical according to the available health time window, and generating corresponding fault early-warning information and corresponding operation management measures according to the health grade. As a preferable scheme of the fault early warning method of the advertisement printing equipment, the invention comprises the steps of superposing the control instruction variable quantity and the feedback deviation variable quantity according to a discrete increment control law to obtain a control output regulating quantity; a limit adjustment margin is set based on the historical control output adjustment amount, and an available control margin reference is calculated using the control output adjustment amount and the limit adjustment margin. As a preferable scheme of the fault early warning method of the advertisement printing equipment, the invention comprises the following specific steps of superposing the control instruction variable quantity and the feedback deviation variable quantity according to a discrete increment control law: Determining a proportional coefficient, an integral coefficient and a differential coefficient based on the historical feedback deviation variation; The control output adjustment amount is calculated using the proportional coefficient, the integral coefficient, the differential coefficient, the control instruction change amount, and the feedback deviation change amount. As an optimal scheme of the fault early warning method of the advertisement printing equipment, the method comprises the following specific steps of: Collecting the running speed and the tension set value of the advertisement printing equipment, wherein the difference between adjacent running speeds is used as the running speed variation, and the difference between adjacent tension set values is used as the tension variation; setting a speed threshold and a tension threshold based on the historical operating speed variation and the historical tension variation; when the running speed variation does not exceed the speed threshold value and the tension variatio