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持續(xù)故障是指故障點(diǎn)的狀態(tài)持續(xù)不變,比如某個(gè)傳感器硬件故障,信號(hào)維持一個(gè)固定的狀態(tài)。這里繼續(xù)分兩種情況討論,如果是持續(xù)作用的信號(hào),則可以用編程軟件直接在線(xiàn)查找到問(wèn)題源。如果邏輯簡(jiǎn)單,甚至可以直接查看輸入(DI)的狀態(tài)來(lái)判斷故障點(diǎn)。比如說(shuō),某個(gè)設(shè)備無(wú)法啟動(dòng),是可以從從容容地進(jìn)行故障排查的。
即使故障原因持續(xù),如果起作用的時(shí)刻比較短,則還是要按照后面說(shuō)明的短時(shí)故障去判斷。比如說(shuō),某移動(dòng)設(shè)備的一個(gè)位置傳感器,只有設(shè)備經(jīng)過(guò)該位置時(shí),信號(hào)才會(huì)短時(shí)出高電平,其他時(shí)刻都是低電平。如果這個(gè)傳感器失電,信號(hào)一直保持低電平,則設(shè)備經(jīng)過(guò)前,故障是不會(huì)表現(xiàn)出來(lái)的。
短時(shí)故障,是指故障原因出現(xiàn)的時(shí)間很短(尤其是偶發(fā)的短時(shí)故障),比如說(shuō),某個(gè)傳感器的信號(hào)線(xiàn)松了,設(shè)備發(fā)生振動(dòng),信號(hào)時(shí)斷時(shí)續(xù),甚至十天半個(gè)月來(lái)一次?;蛘撸到y(tǒng)出現(xiàn)了干擾,某個(gè)信號(hào)偶爾會(huì)不正常反轉(zhuǎn)。短時(shí)故障也指那些故障的狀態(tài)只能在短時(shí)間顯現(xiàn)的情況(前一段描述的情況)。
對(duì)于短時(shí)故障,尤其是那些可能原因比較多的短時(shí)故障,無(wú)法依靠肉眼去長(zhǎng)期跟蹤,比較好的手段就是信號(hào)錄波?;舅悸罚簩惓5妮敵黾翱赡茉颍≒LC變量)都進(jìn)行連續(xù)狀態(tài)記錄。在出現(xiàn)故障時(shí),回看故障時(shí)各變量的狀態(tài)記錄,結(jié)合程序邏輯,就可以判斷出故障點(diǎn)或者故障范圍,然后,縮小范圍繼續(xù)錄波,直到定位出故障點(diǎn)。
常用的錄波手段包括:HMI軟件的變量記錄、編程軟件的曲線(xiàn)記錄、第三方通用錄波軟件。
HMI軟件的變量記錄(也指SCADA軟件),就是在HMI里將需要記錄的變量都添加進(jìn)去,并設(shè)置成連續(xù)記錄,然后用波形查看控件進(jìn)行波形的回放。這種方法對(duì)于臨時(shí)查故障是極不方便的,因?yàn)?,需要把HMI畫(huà)面停下來(lái)進(jìn)行一次畫(huà)面開(kāi)發(fā),然后再運(yùn)行起來(lái),工作量不小,且影響操作人員的使用。另外,HMI的變量刷新速度一般較低,比如0.5s刷新周期,PLC的程序執(zhí)行周期一般在100ms之內(nèi),因此,會(huì)遺漏很多細(xì)節(jié)。
PLC編程軟件能記錄曲線(xiàn)的并不多,并且也不太容易操作。比如STEP7是無(wú)法記錄曲線(xiàn)的,博圖具有軌跡功能(限于S7-1200、S7-1500等),但是其本質(zhì)是PLC內(nèi)進(jìn)行記錄,然后上傳顯示,優(yōu)點(diǎn):可以實(shí)現(xiàn)每周期的記錄??梢赃M(jìn)行條件觸發(fā)。缺點(diǎn):不能連續(xù)跟蹤,不能脫離龐大的博圖軟件。
第三方通用錄波軟件是指那些能對(duì)多種PLC進(jìn)行連續(xù)錄波的軟件,比較常見(jiàn)的是PLC-ANALYZER、IBA。這兩個(gè)軟件都是國(guó)外的軟件,價(jià)格昂貴,無(wú)免費(fèi)使用部分。一般PLC工程師無(wú)法承受。國(guó)內(nèi)新出現(xiàn)的PLC-Recorder錄波軟件,與PLC-ANALYZER風(fēng)格、性能類(lèi)似,且其大部分功能都可以長(zhǎng)期免費(fèi)使用。
簡(jiǎn)單介紹了錄波軟件,回頭再看短時(shí)故障。根據(jù)故障現(xiàn)象持續(xù)的時(shí)間長(zhǎng)短,要選擇不同的錄波手段。大家可以參照下圖選擇合適的軟件工具:
圖2 PLC錄波軟件的選擇建議
對(duì)于超短時(shí)的故障,需要采用特殊軟件或者特殊方法來(lái)進(jìn)行故障錄波和診斷。某些軟件能讓PLC自己按照掃描周期錄波,然后事后上傳顯示的編程軟件,比如前面提到的博圖軌跡功能。也包括那些通過(guò)PLC編程進(jìn)行數(shù)據(jù)緩沖,然后再打包上傳的專(zhuān)用軟件。
如果無(wú)法用特殊軟件進(jìn)行錄波(比如型號(hào)非常老的PLC),則可以采用拖尾法對(duì)于可疑的信號(hào)進(jìn)行處理,讓信號(hào)的時(shí)間變長(zhǎng),然后利用通用錄波軟件或者HMI對(duì)于處理后的信號(hào)進(jìn)行錄波即可。比如某信號(hào)正常出低電平,懷疑其可能短時(shí)出現(xiàn)了高電平,則可以增加程序,對(duì)其進(jìn)行斷開(kāi)延時(shí),然后記錄斷開(kāi)延時(shí)后的信號(hào)即可(如下圖所示)。對(duì)于可能出現(xiàn)低電平的,則可以增加接通延時(shí)來(lái)進(jìn)行拖尾,甚至兩種延時(shí)同時(shí)增加,進(jìn)行兩個(gè)方向的拖尾。The internal combustion engine itself is also an important application field of sliding bearings. They are mainly used to reduce the friction between the crankshaft and the camshaft during the operation of the engine, and at the same time avoid the damage and failure of the engine. As the requirements for the use of sliding bearings are higher and higher, and the relevant specifications are more and more strict, we need to constantly improve its quality, durability and accuracy. The engine sliding bearing is manufactured by the Miba bearing group located in mcconnelsville, Ohio, and the Miba Gleitlager located in laakirchen, Austria. Since 1949, they have produced a complete set of sliding bearing products for large diesel engines, including bearing shells, bushings and thrust washers.
The main components of the engine sliding bearing are generally made of non alloy steel, but the anti friction pad is developed with alloy materials according to specific specifications. Miba has its own Metallurgical Research Laboratory and regards the development of alloy materials as the core competitiveness of the company. Their surface materials are usually treated by sputtering process (also known as Cathode Evaporation). Sputtering is similar to the manufacturing method of old TV picture tubes, that is, the process of making atoms escape from the cathode under vacuum and forming a thin film on the surface of the object.
The sputtering process is realized by a series of automatic equipment developed by Miba in the 1990s. All processes from laboratory test to production are completed by Miba alone. They are not only used for the production of Miba's own factory but also provided to other manufacturers with similar requirements. In addition to the coating and temperature control unit, each sputtering machine around the main distribution station also provides six vacuum chambers for continuous surface treatment of parts.