CN105137851A - Generator set operation data recorder and record method - Google Patents

Generator set operation data recorder and record method Download PDF

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Publication number
CN105137851A
CN105137851A CN201510225680.1A CN201510225680A CN105137851A CN 105137851 A CN105137851 A CN 105137851A CN 201510225680 A CN201510225680 A CN 201510225680A CN 105137851 A CN105137851 A CN 105137851A
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data
genset
module
digital signal
fault
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曾永泉
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Dongguan Tuancheng Automation Equipment Co Ltd
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Dongguan Tuancheng Automation Equipment Co Ltd
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Priority to CN201510225680.1A priority Critical patent/CN105137851A/en
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Abstract

The invention discloses a generator set operation data recorder and a record method. Random fault signals generated by a generator set and related data are actively recorded, problems of record limits of operation data and huge redundancy data bulk existing in the generator set in the prior art are solved; the recorded fault data is convenient for technical analysis so as to do further prediction about possible development trends of variables. After multiple experiments for verification, application of the data recorder and the record method makes fault maintenance of the generator sets not limited to one part or a fault point, possible problems are analyzed and solved integrally, hidden faults which are neglected or are not discovered in the past are solved for one time, and further damage is eliminated. The generator set operation data recorder can realize high temperature prevention, strong electrical power damage prevention and external force destroy, further protects internal recorded data, and the generator set operation data recorder is equal to a black box of operation data of the generator set.

Description

Genset service data register and recording method
Technical field
The present invention is about the service data treatment technology of rotating machinery, a kind of for the treatment of coming the register of service data that self generating sets produces and recording method specifically.
Background technology
Generator Set is the key equipment in electric system, improving constantly in recent years along with its rated voltage and capacity, Generator Set is subject to the impact of more electricity, heat, mechanical stress and environmental factor in operational process, these factors will make certain part in genset break down in operation process directly or indirectly, just probably breaks in production, cause huge economic loss, even the consequence of bringing on a disaster property.For ensureing power system security, economy, stable operation, the reliability of Electric Power Generating Equipment, economy and stability are had higher requirement.This just must monitor the various service datas of genset in real time, wherein, is related to the scientific rationality of genset condition monitoring and fault diagnosis scheme.
In the evolution of genset fault diagnosis, the feature extraction of most important, to be also one of the most difficult problem be exactly fault characteristic signals.In a sense, feature extraction can be described as the bottleneck problem in the research of current generator group fault diagnosis, and it is directly connected to the possible development trend of the accuracy of fault diagnosis, the reliability of fault early prediction and variable.
At present, the key issue that industry is badly in need of solving is: a certain parts or trouble spot are no longer limited in the breakdown maintenance of genset, but analyze and solve may be carried out by Problems existing based on overall, the disposable solution of hidden fault can ignored or can't find in the past, damage hidden danger in order to eliminate supervention.
In the past, rely on the monitoring work that engine controller carries out service data, this controller was only monitoring voltage and current parameters, cannot detect the situation of numerous mechanical part.And the engine controller of conventional art can only record the data of the moment that random fault signal occurs, follow-uply cannot carry out according to these data fault diagnosis work genset being carried out to a system; Another kind of situation is: the engine controller of conventional art is by carrying out record to the service data of generator whole process, reach and obtain random fault data object, this record scheme is scientific and reasonable not, and the data volume be recorded to is very huge, and fault signature extracts difficulty.
In sum, unnecessary maintenance down is avoided also to be important.Because the experience in past shows, the moment between down period or after shutdown the most easily produces accident, when genset produces random fault, usually with occurring that current/voltage is abnormal, and TRANSIENT HIGH TEMPERATURE and generation outside destroy.And therefore the electric part in engine controller can be in rugged environment, be subject to instant high-voltage and heavy current is burnt, or the data storage device in control system, when being subject to strong outside destroy, easily causes recorded service data to be damaged.
Summary of the invention
The invention provides a kind of genset service data register and recording method; to solve the limitation of genset service data record and huge redundant data amount problem, and protection can be provided for be recorded to service data when genset generation random fault.
An object of the present invention is, a kind of genset service data register is provided, the record of its random fault data produced in running for genset and data protection, described register comprises: loop-around data buffer memory module, the master control system data cube computation of loop-around data buffer memory module and genset, be buffered in data-carrier store for described master control system is become the real time digital signal sent here, and in described data-carrier store circular buffer one section of preliminary setting data length, and comprise the genset service data of up-to-date real time digital signal; Module is compared in active monitoring, contrasting, carrying out judging the operation of random fault signal, providing foundation for taking further measures, and providing real-time early warning information for described master control system synchronously being become the digital signal sent here with the detection threshold preset; Record module, be connected on trigger circuit, and compare module by trigger circuit with described loop-around data buffer memory module and active monitoring and be electrically connected, record module is controlled by active monitoring and compares module, for compare in active monitoring module judge described random fault signal time, receive and preserve described genset service data in Nonvolatile memery unit, data input isolation is carried out to Nonvolatile memery unit thereupon; Wherein, the trigger source of described trigger circuit is described random fault signal; Wherein, recording module is provided with for holding with PC the FPDP setting up data interaction; Described FPDP is Universal USB interface, RS232 interface or RS485 interface; Described record module comprises: isolated data transmission IC, and being connected for the digital signal being communicated with or isolating between micro-control unit with described Nonvolatile memery unit, is photoelectric isolation module; Insulating power supply module, for providing standby power supply for described micro-control unit, protects the data in described Nonvolatile memery unit not to be damaged because of abnormity of power supply; Protecting sheathing, for described micro-control unit, Nonvolatile memery unit, isolated data transmission IC and insulating power supply module sealing being protected, the inside surface of protecting sheathing is provided with fire-proof heat-insulating layer, and protecting sheathing is high temperature resistant and external force resistance destroys design.
An object of the present invention is; there is provided a kind of genset is run in the random fault data that produce record and the recording method of data protection; the master control system setting up data cube computation with register is provided with in described genset; described recording method comprises: make loop-around data buffer memory module compare module with active monitoring and carry out sampling work simultaneously; reflect the real time digital signal of each assembly real-time running state in uninterrupted acquisition genset, carry out sample cyclic; Real time digital signal described in buffer memory, and simultaneously buffer memory one section of preliminary setting data length and historical data consecutive with up-to-date real time digital signal, synchronously carry out uninterruptedly upgrading described historical data, to make in buffer memory device always to retain one section of up-to-date genset service data, for subsequent cell transmission; Synchronously described real time digital signal and predefined detection threshold are carried out active comparison, judge random fault data, generate fault data and store triggering command, and real-time early warning information is provided; Store triggering command by hardware trigger circuit according to described fault data, the service data of genset described in buffer memory device is write in recording unit automatically; Described recording unit stores triggering command according to fault data and carries out data input insulation blocking; Recording unit is held by FPDP and PC and sets up data interaction; Recording unit is encapsulated in recording unit can be prevented to be subject to destroying under high temperature and External Force Acting in external environment condition protecting sheathing in; Described real-time early warning information, is sent by early warning output module by showing the mode at interface or mail sending or SMS notification with predefined notification strategy; Described real time digital signal comprises information working time of genset; Described real time digital signal comprises: the temperature value of the three-phase current effective value of genset, three-phase voltage effective value, exciting current mean value, field voltage mean value, generator frequency, each stator winding and each rotary part; The temperature value of described rotary part comprises the operating temperature value of multiple bearing in genset; Described detection threshold comprises: fault data stores triggering command lower limit and higher limit; Numerical value in described real time digital signal and predefined fault data are stored triggering command lower limit and higher limit contrasts, judge random fault data, produce and store real-time early warning information; The sample period time of described sample cyclic is less than or equal to one second.
Beneficial effect of the present invention is: the present invention is applicable to being applied on the genset of relatively high power (more than 1MW); random fault data for producing genset are carried out active and are extracted record and data protection; and; the present invention is constructed to be permeable to anti-external environment condition high temperature and outside destroy; avoid being damaged in rugged surroundings for the protection of electric elements inside; reach protection genset service data object, be equivalent to data black box module.
Wherein, due to record the genset service data of preserving and only comprise the failure message of one section of preliminary setting data length necessity, data volume is reduced greatly, without the need to mass memory unit and produce huge redundant data amount problem.Greatly reduce outfit of equipment and have cost.
Wherein, extract the genset service data of preserving and be configured with the historical data causing producing random fault data, be namely random fault lead because of, and the failure message that up-to-date real time digital signal comprises; Genset service data is convenient to carry out fault data technical Analysis, to do further prediction to the possible development trend of variable.By carrying out technical Analysis and prediction to genset service data, the system that can reach solves genset existing issue and potential problems object.And the present invention is by obtaining great economic benefit to the continuous monitoring of genset key project: the first reduces the damage of genset, reduces the expense more required for exchange device; It two is by Predictive Maintenance state, saves stop time, therefore can greatly reduce the power loss caused thus.
The present invention can be used for the prophylactic repair mode replaced in the past, and its principle is: only have when monitoring, analysis and prediction result shows just to keep in repair when being necessary maintenance.And, by carrying out technical Analysis to genset service data, can by the character of the fault determined and position, on purpose overhaul, and the historic state of analyzing generator group and current state, and prediction development subsequently, be beneficial to and grasp research genset Common Faults Characters, set up failure cause collection and fault reasoning mechanism.
Verify through many experiments, application of the present invention makes the breakdown maintenance of genset no longer limit to a certain parts or a certain trouble spot, but analyze and solve may be carried out by Problems existing based on overall, the disposable solution of hidden fault can ignored or can't find in the past, elimination supervention damages, and saves a large amount of maintenance cost, greatly promotes the effectiveness of maintenance, make genset keep optimal runnability, extend the serviceable life of genset.
Accompanying drawing explanation
Accompanying drawing is used to provide a further understanding of the present invention, and forms a part for instructions, is used from explanation the present invention, is not construed as limiting the invention, in the accompanying drawings with embodiment one below.
Fig. 1 is workflow diagram of the present invention.
Fig. 2 is the circuit theory diagrams recording module in the present invention.
Embodiment
Below in conjunction with accompanying drawing, the specific embodiment of the present invention is described.Should be understood that, embodiment described herein, only for instruction and explanation of this explanation, is not limited to the present invention.
As shown in Figure 1, the genset service data active detecting register of the present embodiment comprises: loop-around data buffer memory module, the master control system 200(of loop-around data buffer memory module and genset comprises: signal conditioning circuit, A/D modular converter and DSP unit) data cube computation, be buffered in data-carrier store for described master control system 200 is become the real time digital signal sent here, and in described data-carrier store circular buffer one section of preliminary setting data length, and comprise the genset service data of up-to-date real time digital signal; Module is compared in active monitoring, contrasting, carrying out judging the operation of random fault signal, providing foundation for taking further measures, and providing real-time early warning information for described master control system 200 synchronously being become the digital signal sent here with the detection threshold preset; Record module 100, be connected on trigger circuit, and compare module by trigger circuit with described loop-around data buffer memory module and active monitoring and be electrically connected, record module 100 is controlled by active monitoring and compares module, for compare in active monitoring module judge described random fault signal time, receive and preserve described genset service data in Nonvolatile memery unit, data input isolation is carried out to Nonvolatile memery unit thereupon; Wherein, the trigger source of described trigger circuit is described random fault signal; Wherein, record module 100 to be provided with for holding with PC the FPDP setting up data interaction.
The FPDP of the present embodiment is preferably Universal USB interface 106(standard A type USB2.0 or standard A type USB3.0 connector), by holding 300 direct-connected with PC, use the usb 1 06 of PC end 300 to power, carry out the genset service data in reading non-volatile storage unit.
One as technical solution of the present invention is preferred, and genset service data active detecting register of the present invention is provided with control panel; In another embodiment, control panel is provided with described usb 1 06, RS232 interface and RS485 interface, and usb 1 06, RS232 interface and RS485 interface are electrically connected, for holding 300 to realize remote data transmission with PC with record module 100; Conveniently 300 terminal devices such as grade are held to be connected with PC when practical application.Real-time early warning information by PC end 300 and early warning output module (early warning output module is SMS alarm circuit, comprise: GSM mobile handset module or GPRS mobile module or CDMA mobile module) send, utilizing GPRS network by described real-time early warning information transmission to connecting on main frame on internet or mobile phone terminal, to realize real-time early warning information with the form remote notification of graph-text content to user.
The early warning output module of the present embodiment is connected to genset service data active detecting register end or PC end, according to described real-time early warning information triggering work.
The record module 100 of the present embodiment comprises: isolated data transmission IC, and being connected for the digital signal being communicated with or isolating between micro-control unit with described Nonvolatile memery unit, is photoelectric isolation module; When genset generation random fault, when producing strong curcent surge, this photoelectric isolation module protection Nonvolatile memery unit is not burnt by forceful electric power;
Insulating power supply module 104, for providing standby power supply for described micro-control unit, protects the data in described Nonvolatile memery unit not to be damaged because of abnormity of power supply;
The protecting sheathing of the present embodiment is configured in the rugged surroundings can resisting two degrees high temperature and uses, and can resist strong external impacts destruction; Described micro-control unit, Nonvolatile memery unit, isolated data transmission IC and insulating power supply module 104 are sealed in protecting sheathing, and the inside surface of protecting sheathing is provided with fire-proof heat-insulating layer, provides excellent heat radiation insulating effect.Protecting sheathing and the above-mentioned electric unit be sealed in protecting sheathing form the black box of genset service data.
The loop-around data buffer memory module of the present embodiment is used for the genset service data of circular buffer one section of preliminary setting data length;
Suppose: described genset service data is preset as the data length of 100 seconds, this data length contains up-to-date real time data and with the historical data of up-to-date real time data toward last hundred second time period, form the data volume needed for one section of enough data processing, when there is random fault in genset, carry out being kept in Nonvolatile memery unit, for providing rationally foundation accurately for technical Analysis; Therefore, the data volume of required record greatly reduces, and solves huge redundant data amount problem, thus without the need to using the memory device of magnanimity.Reach the feature extraction object to fault characteristic signals.
The recording method of the genset service data of the present embodiment comprises:
The master control system 200 of genset service data active detecting register and genset is set up data cube computation, the course of work and principle are: master control system 200 gathers the three-phase current of genset end, three-phase voltage, exciting current, field voltage, the original signal of the temperature of each stator winding and each rotary part, through signal condition, converting simulating signal to digital signal through A/D conversion is again sent in DSP unit, carry out the three-phase current effective value that digital processing (carrying out root mean square calculation) draws genset end, three-phase voltage effective value, exciting current mean value, field voltage mean value, generator frequency, the temperature value of each stator winding and each rotary part, be sent to genset service data active detecting register,
Make loop-around data buffer memory module compare module with active monitoring and carry out sampling work simultaneously, uninterrupted acquisition DSP unit becomes the real time digital signal of each assembly real-time running state of reflection genset sent here, carries out sample cyclic; The sample period time of sample cyclic is less than or equal to one second;
Real time digital signal described in the real-time buffer memory of loop-around data buffer memory module, and carry out circular buffer one section of preliminary setting data length and historical data consecutive with up-to-date real time digital signal, and synchronously carry out uninterruptedly upgrading described historical data, to make in buffer memory device always to retain one section of up-to-date genset service data, for subsequent cell transmission;
Active monitoring is compared module and synchronously described real time digital signal and predefined detection threshold is carried out active comparison, judges random fault data, generates fault data and stores triggering command, and provide real-time early warning information;
Triggering command is stored by hardware trigger circuit, in the recording unit that the genset service data in described buffer memory device is write in described record module 100 automatically according to described fault data; Described recording unit stores triggering command according to fault data and carries out data input insulation blocking; Therefore, the genset service data that recording unit is recorded to be genset in the operational factor for the previous period that breaks down, do not lose in the operating mode that genset breaks down, ensure that real-time and accuracy.
Recording unit is provided with FPDP, makes to hold 300 to set up data interaction with PC by FPDP.
As another kind of optimal technical scheme of the present invention, described real-time early warning information is passed through the mode of showing interface or mail sending or SMS notification with predefined notification strategy, sent by early warning output module, with the form remote notification of graph-text content to user.
The real time digital signal of the present embodiment comprises the initial operation time of genset and runs total duration information.
The real time digital signal of the present embodiment comprises: the temperature value of the three-phase current effective value of genset, three-phase voltage effective value, exciting current mean value, field voltage mean value, generator frequency, each stator winding and each rotary part; The temperature value of rotary part wherein comprises the operating temperature value of multiple bearing in genset.
The detection threshold of the present embodiment comprises: fault data stores triggering command lower limit and higher limit; Numerical value in described real time digital signal and predefined fault data are stored triggering command lower limit and higher limit contrasts, judge random fault data, produce and store real-time early warning information.
In technical scheme of the present invention, recording unit is encapsulated in recording unit can be prevented to be subject to destroying under high temperature and External Force Acting in external environment condition protecting sheathing in; The protecting sheathing of the present embodiment is enclosed construction, for the synthetic material of high temperature resistant and resistance to external impacts or alloy are made, fire-proof heat-insulating layer is located on the inside surface of protecting sheathing, for isolated heat radiation, make the micro-control unit in built-in protecting sheathing, Nonvolatile memery unit, isolated data transmission IC and insulating power supply module 104 can tolerate the continuous high temperature of less than 260 degrees Celsius; Meanwhile, the impact that protecting sheathing is used for bearing each axial outer impulsive force does not produce obvious deformation, protects above-mentioned electric part not by physical damage, thus forms protection reliably to the genset service data in Nonvolatile memery unit.
The isolated data transmission IC of the present embodiment also can have the hardware of same function, as photoelectric isolation module or photoelectrical coupler 103 for other; Micro-control unit refers to MCU101; Nonvolatile memery unit refers to EEPROM102.
Above embodiment is only for illustration of the present invention; and be not limitation of the present invention; the those of ordinary skill of relevant technical field; without departing from the spirit and scope of the present invention; can also make a variety of changes and modification; therefore all equivalent technical schemes also belong to category of the present invention, and scope of patent protection of the present invention should be defined by the claims.

Claims (10)

1. a genset service data register, the record of its random fault data produced in running for genset and data protection, described register comprises:
Loop-around data buffer memory module, the master control system data cube computation of loop-around data buffer memory module and genset, be buffered in data-carrier store for described master control system is become the real time digital signal sent here, and in described data-carrier store circular buffer one section of preliminary setting data length, comprise the genset service data of up-to-date real time digital signal;
Module is compared in active monitoring, contrasting, carrying out judging the operation of random fault signal, providing foundation for taking further measures, and providing real-time early warning information for described master control system synchronously being become the digital signal sent here with the detection threshold preset;
Record module, be connected on trigger circuit, and compare module by trigger circuit with described loop-around data buffer memory module and active monitoring and be electrically connected, record module is controlled by active monitoring and compares module, for compare in active monitoring module judge described random fault signal time, receive the genset service data of preservation circular buffer part in Nonvolatile memery unit, data input isolation is carried out to Nonvolatile memery unit thereupon; Wherein, the trigger source of described trigger circuit is described random fault signal; Record module is provided with for holding with PC the FPDP setting up data interaction.
2. detection record device according to claim 1, is characterized in that, described FPDP is Universal USB interface, RS232 interface or RS485 interface.
3. detection record device according to claim 1, is characterized in that, described record module comprises:
Isolated data transmission IC, being connected for the digital signal being communicated with or isolating between micro-control unit with described Nonvolatile memery unit, is photoelectric isolation module;
Insulating power supply module, for providing standby power supply for described micro-control unit, protects the data in described Nonvolatile memery unit not to be damaged because of abnormity of power supply;
Protecting sheathing, for described micro-control unit, Nonvolatile memery unit, isolated data transmission IC and insulating power supply module sealing being protected, the inside surface of protecting sheathing is provided with fire-proof heat-insulating layer, and protecting sheathing is high temperature resistant and external force resistance destroys design.
4. the random fault data produced in running genset record and the recording method of data protection, and be provided with the master control system setting up data cube computation with register in described genset, it is characterized in that, described recording method comprises:
Make loop-around data buffer memory module compare module with active monitoring and carry out sampling work simultaneously, reflect the real time digital signal of each assembly real-time running state in uninterrupted acquisition genset, carry out sample cyclic;
Real time digital signal described in the real-time buffer memory of loop-around data buffer memory module, and carry out circular buffer one section of preliminary setting data length and historical data consecutive with up-to-date real time digital signal, and synchronously carry out uninterruptedly upgrading described historical data, to make in buffer memory device always to retain one section of up-to-date genset service data, for subsequent cell transmission;
Active monitoring is compared module and synchronously described real time digital signal and predefined detection threshold is carried out active comparison, judges random fault data, generates fault data and stores triggering command, and provide real-time early warning information;
Store triggering command by hardware trigger circuit according to described fault data, the service data of genset described in buffer memory device is write in recording unit automatically;
Described recording unit stores triggering command according to fault data and carries out data input insulation blocking;
Recording unit is held by FPDP and PC and sets up data interaction.
5. method according to claim 4, is characterized in that, described real-time early warning information, is sent by early warning output module by showing the mode at interface or mail sending or SMS notification with predefined notification strategy.
6. method according to claim 4, is characterized in that, described real time digital signal comprises information working time of genset.
7. method according to claim 4, it is characterized in that, described real time digital signal comprises: the temperature value of the three-phase current effective value of genset, three-phase voltage effective value, exciting current mean value, field voltage mean value, generator frequency, each stator winding and each rotary part;
The temperature value of described rotary part comprises the operating temperature value of multiple bearing in genset.
8. method according to claim 7, is characterized in that, described detection threshold comprises: fault data stores triggering command lower limit and higher limit;
Numerical value in described real time digital signal and predefined fault data are stored triggering command lower limit and higher limit contrasts, judge random fault data, produce and store real-time early warning information.
9. method according to claim 4, is characterized in that, the sample period time of described sample cyclic is less than or equal to one second.
10. method according to claim 4, is characterized in that, recording unit is encapsulated in recording unit can be prevented to be subject to destroying under high temperature and External Force Acting in external environment condition protecting sheathing in.
CN201510225680.1A 2015-05-06 2015-05-06 Generator set operation data recorder and record method Pending CN105137851A (en)

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Application publication date: 20151209