CN110671341A - Centrifugal pump impeller damage diagnosis method and device based on sensorless monitoring technology - Google Patents

Centrifugal pump impeller damage diagnosis method and device based on sensorless monitoring technology Download PDF

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CN110671341A
CN110671341A CN201911064918.1A CN201911064918A CN110671341A CN 110671341 A CN110671341 A CN 110671341A CN 201911064918 A CN201911064918 A CN 201911064918A CN 110671341 A CN110671341 A CN 110671341A
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signal
centrifugal pump
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transient current
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孙慧
陈宁
周逸龙
王军
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Jiangsu University of Science and Technology
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
    • F04D15/0088—Testing machines

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  • Control Of Non-Positive-Displacement Pumps (AREA)
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Abstract

The invention discloses a centrifugal pump impeller damage diagnosis method and device based on a sensorless monitoring technology, which are used for collecting transient current signals of a driving motor of a centrifugal pump, extracting running characteristic components of the centrifugal pump by utilizing a cyclostationary theory to carry out time-frequency joint analysis on the current signals, and judging whether impeller damage occurs or not. The invention can realize the running state monitoring of the centrifugal pump without approaching running equipment by measuring and analyzing the current signal of the driving motor of the centrifugal pump, the device is convenient and flexible to install and use, the installation cost is low, meanwhile, the running characteristic information of the centrifugal pump can be reflected in the current signal in real time, the information integration level is high, and the measurement reliability is high; the singular value decomposition is adopted to eliminate the power frequency component in the transient current, the modulation influence of the singular value decomposition on the current signal is reduced, the signal processing is based on the cyclostationary theory, and the analysis result is more accurate and reliable.

Description

Centrifugal pump impeller damage diagnosis method and device based on sensorless monitoring technology
Technical Field
The invention relates to a fluid mechanical testing method and a device thereof, in particular to a centrifugal pump impeller damage diagnosis method and a device thereof.
Background
Centrifugal pumps are widely used in the industrial field. The centrifugal pump is easy to have mechanical failure, the performance of the centrifugal pump is reduced, and the energy consumption is increased. In mechanical failure, impeller cracks are common. Impeller cracks may be caused by erosion of the fluid or solid particles in the fluid, and such cracks may disrupt the rotational balance of the centrifugal pump, thereby reducing operational stability. Therefore, it is necessary to monitor the operating state of the centrifugal pump to ensure the efficiency and reliability of the operation.
The sensorless monitoring technology can be used for monitoring the working condition of the centrifugal pump. According to the technology, an asynchronous motor driving a pump to operate is used as a torque sensor, and the characteristics of the operation state of the pump are extracted by analyzing the time-frequency characteristics of a motor stator current signal, so that the working condition monitoring is realized. The technology can greatly reduce the cost of the traditional monitoring method, simplify the installation and improve the accuracy and reliability of the monitoring result.
A rotating blade fault indirect diagnosis technology (China: China, publication number: 101592590A, publication date: 2009-12-02), a stochastic resonance semi-open type impeller crack fault detection method of a centrifugal compressor (China: China, publication number: 104165925A, publication date: 2014-11-26) and a crack fault identification method of a centrifugal compressor semi-open type impeller (China: China, publication number: 104236871A, publication date: 2014-12-24) all disclose that an impeller operation state signal is obtained by a sensor, but the defects are as follows: the sensor needs to be close to the equipment to be detected during installation, the installation cost is high, and the operation is complex; the sensor has multiple signal transmission paths, poor anti-interference capability and low reliability; the detection device has poor working environment and higher maintenance cost.
Disclosure of Invention
The purpose of the invention is as follows: in view of the above problems, it is an object of the present invention to provide a method for diagnosing damage of an impeller of a centrifugal pump based on a sensorless monitoring technique, which improves the accuracy of the monitoring result, and it is another object of the present invention to provide a device for implementing the method.
The technical scheme is as follows: a centrifugal pump impeller damage diagnosis method based on a sensorless monitoring technology calculates respective related parameters and compares the related parameters according to the following steps for a centrifugal pump driving motor which operates under actual working conditions and design working conditions:
step 1, collecting transient current signals of a driving motor, converting the transient current signals into voltage signals, and analyzing and calculating the voltage signals;
step 2, analyzing the acquired transient current signal, and eliminating a power frequency component in the transient current by utilizing singular value decomposition;
step 3, analyzing the acquired transient current signal based on the cyclostationary theory, and calculating a cyclic autocorrelation function Rx(τ, α), and a cyclic autocorrelation function Rx(τ, α) standard deviation of slice components;
step 4, comparing the standard deviation sigma under the actual working condition with the standard deviation sigma under the design working condition0When σ > (1.05-1.10) σ0If the running state of the centrifugal pump deviates from the design working condition, otherwise, the running state of the centrifugal pump is required to be further calculated and analyzed;
step 5, extracting blade passing frequency alpha1At slice component Rx(τ，α1) And Fourier transform is carried out to obtain the amplitude of the main frequency component, and the amplitude A of the main frequency component under the actual working condition is compared1Amplitude of main frequency component in fault-free normal operation under design condition
Figure BDA0002259018180000021
When in use
Figure BDA0002259018180000022
The time is that the impeller is damaged, otherwise, the impeller is normal; and extracting a cyclic slice spectrum corresponding to the passing frequency of N (N is less than or equal to 6) integral multiples of blades in the transient current signal for analysis so as to judge the number of damaged impellers.
Further, step 2 specifically comprises:
(1) assuming that a matrix A is formed by the collected discrete transient current signal sequence, and a real matrix A belongs to Rm×nExistence of an orthogonal matrix U ∈ Rm×mAnd V ∈ Rm×nThen the sequence may constitute a matrix:
A＝UΛVT
in the formula, Λ is a diagonal matrix, the rank of Λ is r, r is less than or equal to min (m, n), and nonzero diagonal elements are singular value elements of the matrix A and are arranged in a descending order;
(2) carrying out SVD on the matrix A to obtain a series of singular values sigmaiAnd the corresponding sub-matrix AiThe submatrix AiFrom singular value vectors uiAnd viComposition of each vector uiAnd viA rectangular coordinate system may be constructed so that the characteristic information in matrix A is decomposed into orthogonal vectors ui、viA series of subspaces are formed:
Figure BDA0002259018180000023
in the formula uiAnd viThe ith left and right singular vectors, σ, of the matrix AiIs the i-th singular value of the matrix A, AiIs a sub-matrix;
(3) the power grid frequency component is a main component in the current signal, and therefore corresponds to the first subspace, while the weak signal capable of reflecting the operation characteristic information of the centrifugal pump is decomposed into other different subspaces, so that the power grid frequency component is expressed as the decomposed first component:
Figure BDA0002259018180000024
in the formula u1、σ1、
Figure BDA0002259018180000025
Is the first component after decomposition
Figure BDA0002259018180000026
The construction matrix of (1);
(4) removal of grid frequency components in current signal A
Figure BDA0002259018180000031
The signal of the power frequency component in the rejection current can be obtained and expressed as:
Figure BDA0002259018180000032
further, in the step 3,
cyclic autocorrelation function Rx(τ, α) is specifically:
Figure BDA0002259018180000033
cyclic autocorrelation function RxThe standard deviation of the (τ, α) slice components is specifically:
Figure BDA0002259018180000034
wherein, denotes conjugation, tau is time delay factor, and the second order cyclostationarity of the signal denotes that all time t satisfies Rx(t，τ)＝Rx(T + T, τ), where T0Is a cycle period, alpha is 1/T as a basic cycle frequency, N is RxNumber of points in (tau, alpha) slice component, miDenotes the value of each point, μ denotes the average value of all points, N denotes an integer from-N to N, and j denotes an imaginary number.
A device for realizing the centrifugal pump impeller damage diagnosis method based on the sensorless monitoring technology comprises the following steps:
the signal acquisition module is used for acquiring transient current signals of the driving motor when the centrifugal pump operates;
the signal conditioning module is used for converting the transient current signal acquired by the signal acquisition module into a voltage signal;
the signal processing module is used for analyzing and processing the voltage signal converted by the signal conditioning module;
the storage module is connected with the signal conditioning module and the signal processing module and used for storing data;
the display module is connected with the signal processing module and used for displaying data;
and the power supply module is respectively connected with the signal acquisition module, the signal conditioning module, the signal processing module, the storage module and the display module and is used for operating the device.
Furthermore, the signal acquisition module is a Hall current sensor, one interface of the signal acquisition module is connected with the signal conditioning module, and the other interface of the signal acquisition module is connected with a three-phase alternating current live wire of the centrifugal pump driving motor.
Further, the storage module is an SD storage card, and the display module is an LCD touch control display device.
Further, the signal conditioning module converts the transient current signal collected by the signal collecting module into a 0-3V voltage signal.
Has the advantages that: compared with the prior art, the invention has the advantages that: 1. based on a sensorless monitoring technology, the current signal of the driving motor of the centrifugal pump is measured and analyzed, the running state monitoring of the centrifugal pump can be realized without approaching running equipment, and the device is convenient and flexible to install and use; 2. the device has low installation cost, meanwhile, the running characteristic information of the centrifugal pump can be reflected in a current signal in real time, the information integration level is high, in addition, the dynamic information of the centrifugal pump is reflected by the air gap magnetic field change of the stator winding and the rotor winding, the information transmission path is few, the anti-interference capability is strong, and the measurement reliability is high; 3. the method has the advantages that power frequency components in transient current are eliminated by singular value decomposition, the modulation influence of the power frequency components on current signals is reduced, signal processing is based on a cyclostationary theory, fault characteristic information can be accurately extracted by analyzing slice components in a signal cyclic autocorrelation function, signal interference caused by unstable operation due to partial working conditions is eliminated, and an analysis result is more accurate and reliable.
Drawings
FIG. 1 is a schematic structural view of an apparatus for carrying out the method for diagnosing impeller breakage of a centrifugal pump according to the present invention;
FIG. 2 is a flow chart of the method for diagnosing impeller breakage of a centrifugal pump according to the present invention;
FIG. 3 is a flow chart of the method for eliminating the power frequency component in the transient current in step 2;
FIG. 4 is a flow chart of the signal analysis process performed in steps 3-5 of the method.
Detailed Description
The invention will be further elucidated with reference to the drawings and specific examples, which are intended to illustrate the invention and are not intended to limit the scope of the invention.
A centrifugal pump impeller breakage diagnosis device comprising: the device comprises a signal acquisition module, a signal conditioning module, a signal processing module, a storage module, a display module and a power supply module. As shown in fig. 1, the signal acquisition module adopts a hall current sensor 1, one interface of which is connected with the signal conditioning module 2, and the other interface of which is connected with a three-phase alternating current live wire 41 of a driving motor 4 for driving the centrifugal pump 3 to work, and is used for acquiring transient current signals of the driving motor when the centrifugal pump operates. The signal processing module is a DSP signal processing module, the storage module is an external SD storage card, the display module is an LCD touch control display device, and the power supply module is respectively connected with the signal acquisition module, the signal conditioning module, the signal processing module, the storage module and the display module and used for running the device.
As shown in the attached figure 2, the method for diagnosing the impeller damage of the centrifugal pump by the device calculates and compares the relevant parameters of the driving motor of the centrifugal pump which operates under the actual working condition and the design working condition according to the following steps:
step 1, acquiring transient current signals of a driving motor through a signal acquisition module, converting the transient current signals into 0-3V voltage signals through a signal conditioning module, and storing the voltage signals by a storage module for analysis and calculation of a signal processing module.
Step 2, the signal processing module analyzes the acquired transient current signal, and eliminates a power frequency component in the transient current by singular value decomposition, as shown in fig. 3, specifically:
(1) assuming that a matrix A is formed by the collected discrete transient current signal sequence, and a real matrix A belongs to Rm×nExistence of an orthogonal matrix U ∈ Rm×mAnd V ∈ Rm×nThen the sequence may constitute a matrix:
A＝UΛVT
in the formula, Λ is a diagonal matrix, the rank of Λ is r, r is less than or equal to min (m, n), and nonzero diagonal elements are singular value elements of the matrix A and are arranged in a descending order;
because Λ is a diagonal matrix, the matrix A can be represented as a sum form of r m × n order submatrices with the rank of 1 after SVD decomposition;
(2) carrying out SVD on the matrix A to obtain a series of singular values sigmaiAnd the corresponding sub-matrix AiThe submatrix AiFrom singular value vectors uiAnd viComposition of each vector uiAnd viA rectangular coordinate system may be constructed so that the characteristic information in matrix A is decomposed into orthogonal vectors ui、viA series of subspaces are formed:
Figure BDA0002259018180000051
in the formula uiAnd viThe ith left and right singular vectors, σ, of the matrix AiIs the i-th singular value of the matrix A, AiIs a sub-matrix;
(3) the power grid frequency component is a main component in the current signal, and therefore corresponds to the first subspace, while the weak signal capable of reflecting the operation characteristic information of the centrifugal pump is decomposed into other different subspaces, so that the power grid frequency component is expressed as the decomposed first component:
Figure BDA0002259018180000052
in the formula u1、σ1、
Figure BDA0002259018180000053
Is the first component after decomposition
Figure BDA0002259018180000054
The construction matrix of (1);
(4) removal of grid frequency components in current signal A
Figure BDA0002259018180000055
The signal of the power frequency component in the rejection current can be obtained and expressed as:
Figure BDA0002259018180000056
step 3, as shown in fig. 4, the signal processing module analyzes the acquired transient current signal based on the cyclostationary theory to calculate the cyclic autocorrelation function Rx(τ, α), and a cyclic autocorrelation function RxStandard deviation of (τ, α) slice components.
Cyclic autocorrelation function Rx(τ, α) is specifically calculated by the following formula:
Figure BDA0002259018180000057
cyclic autocorrelation function RxThe standard deviation of the (τ, α) slice components is specifically calculated by the following formula:
Figure BDA0002259018180000061
wherein, denotes conjugation, tau is time delay factor, and the second order cyclostationarity of the signal denotes that all time t satisfies Rx(t，τ)＝Rx(T + T, τ), where T0Is a cycle period, alpha is 1/T as a basic cycle frequency, N is RxNumber of points in (tau, alpha) slice component, miDenotes the value of each point, μ denotes the average value of all points, N denotes an integer from-N to N, and j denotes an imaginary number.
Step 4, as shown in FIG. 4, recording the standard deviation sigma under actual working condition and the standard deviation sigma under design working condition0. Slice component R at 0Hzx(τ, 0) represents stationary information in the signal and the waveform τ -0 is symmetrically distributed, and the energy in the current signal is mainly concentrated at τ -0. When the centrifugal pump operates under the design working condition, the operation is stable, the fluctuation is small, otherwise, the fluctuation is large, the signal is unstable, and the circulation autocorrelation function R of the comparative current signal can be calculatedxThe standard deviation of the (tau, alpha) slice component is used as the judgment basis.
Considering the error in actual measurement, when the comparison result is σ > (1.05-1.10) σ0The time indicates that the centrifugal pump deviates from the designed working condition and the reverse indicates that the centrifugal pump deviatesIf the heart pump runs near the designed working condition point, the running state of the heart pump needs to be further calculated and analyzed; the comparison result is accessed by the storage module and transmitted to the display module for displaying.
Step 5, as shown in figure 4, extracting the blade passing frequency alpha1At slice component Rx(τ，α1) And Fourier transform is carried out to obtain the amplitude of the main frequency component, and the amplitude A of the main frequency component under the actual working condition is compared1Amplitude of main frequency component in fault-free normal operation under design condition
Figure BDA0002259018180000062
When in use
Figure BDA0002259018180000063
The time is that the impeller is damaged, otherwise, the impeller is normal; the comparison result is accessed by the storage module and transmitted to the display module for displaying.
On the basis, N (N is less than or equal to 6) integral multiple blade passing frequency corresponding circulating slice spectrums in the transient current signal are sequentially extracted for analysis, main frequency components (N times BPF) and sidebands thereof in the slice spectrums, and integral multiple harmonic components of the main frequency components are frequency characteristic components reflecting corresponding faults, the fault frequency amplitude can be used as a fault diagnosis index, the circulating slice spectrums corresponding to N (N is less than or equal to 6) integral multiple BPF are sequentially analyzed according to the index, and the number of damaged impellers can be judged.
Compared with the conventional vibration method, the current method has the following advantages:
1. the vibration signals in different directions are analyzed by extracting the same characteristic frequency, so that different results can be obtained, and the fault diagnosis result obtained by adopting the vibration signal analysis technology can be influenced by the measuring point. The invention carries out fault diagnosis by analyzing the current signal without considering the problem of measuring points, thereby greatly simplifying the work of signal measurement and analysis processing;
2. although the cyclic spectrum analysis technology can accurately demodulate specific frequency components in the signals, improve the signal-to-noise ratio and reduce the interference of other harmonic components, a large number of redundant harmonic frequency components still exist in the cyclic slice spectrum of the vibration signals in the fault state, and the interference is caused to the observation results. When the impeller of the centrifugal pump is damaged, the fluctuation of the vibration signal becomes unstable along with the increase of the damaged number of the blades, but based on the cycle stationary theory, the characteristic frequency slice spectrum in the vibration signal is extracted, and information related to the occurrence of the fault cannot be obtained, so that the vibration signal is not suitable for diagnosing the damaged fault of the impeller.

Claims (7)

1. A centrifugal pump impeller damage diagnosis method based on a sensorless monitoring technology is characterized in that: for centrifugal pump driving motors operating under actual working conditions and design working conditions, calculating and comparing relevant parameters of the centrifugal pump driving motors according to the following steps:
step 1, collecting transient current signals of a driving motor, converting the transient current signals into voltage signals, and analyzing and calculating the voltage signals;
step 2, analyzing the acquired transient current signal, and eliminating a power frequency component in the transient current by utilizing singular value decomposition;
step 3, analyzing the acquired transient current signal based on the cyclostationary theory, and calculating a cyclic autocorrelation function Rx(τ, α), and a cyclic autocorrelation function Rx(τ, α) standard deviation of slice components;
step 4, comparing the standard deviation sigma under the actual working condition with the standard deviation sigma under the design working condition0When σ > (1.05-1.10) σ0If the running state of the centrifugal pump deviates from the design working condition, otherwise, the running state of the centrifugal pump is required to be further calculated and analyzed;
step 5, extracting blade passing frequency alpha1At slice component Rx(τ，α1) And Fourier transform is carried out to obtain the amplitude of the main frequency component, and the amplitude A of the main frequency component under the actual working condition is compared1Amplitude of main frequency component in fault-free normal operation under design condition
Figure FDA0002259018170000014
When in use
Figure FDA0002259018170000013
The time is that the impeller is damaged, otherwise, the impeller is normal; and extracting a cyclic slice spectrum corresponding to the passing frequency of N (N is less than or equal to 6) integral multiples of blades in the transient current signal for analysis so as to judge the number of damaged impellers.
2. The method for diagnosing impeller breakage of a centrifugal pump based on the sensorless monitoring technology according to claim 1, characterized in that: the step 2 specifically comprises the following steps:
(1) assuming that a matrix A is formed by the collected discrete transient current signal sequence, and a real matrix A belongs to Rm×nExistence of an orthogonal matrix V ∈ Rm×mAnd V ∈ Rm×nThen the sequence may constitute a matrix:
A＝UΛyT
in the formula, Λ is a diagonal matrix, the rank of Λ is r, r is less than or equal to min (m, n), and nonzero diagonal elements are singular value elements of the matrix A and are arranged in a descending order;
(2) carrying out SVD on the matrix A to obtain a series of singular values sigmaiAnd the corresponding sub-matrix AiThe submatrix AiFrom singular value vectors uiAnd viComposition of each vector uiAnd viA rectangular coordinate system may be constructed so that the characteristic information in matrix A is decomposed into orthogonal vectors ui、viA series of subspaces are formed:
Figure FDA0002259018170000011
in the formula uiAnd viThe ith left and right singular vectors, σ, of the matrix AiIs the i-th singular value of the matrix A, AiIs a sub-matrix;
(3) the power grid frequency component is a main component in the current signal, and therefore corresponds to the first subspace, while the weak signal capable of reflecting the operation characteristic information of the centrifugal pump is decomposed into other different subspaces, so that the power grid frequency component is expressed as the decomposed first component:
Figure FDA0002259018170000021
in the formula u1、σ1、
Figure FDA0002259018170000022
Is the first component after decomposition
Figure FDA0002259018170000023
The construction matrix of (1);
(4) removal of grid frequency components in current signal A
Figure FDA0002259018170000024
The signal of the power frequency component in the rejection current can be obtained and expressed as:
3. the method for diagnosing impeller breakage of a centrifugal pump based on the sensorless monitoring technology according to claim 1, characterized in that: in the step 3, the step of the method is that,
cyclic autocorrelation function Rx(τ, α) is specifically:
Figure FDA0002259018170000026
cyclic autocorrelation function RxThe standard deviation of the (τ, α) slice components is specifically:
Figure FDA0002259018170000027
wherein, denotes conjugation, tau is time delay factor, and the second order cyclostationarity of the signal denotes that all time t satisfies Rx(t，τ)＝Rx(T + T, τ), where T0Is a cycle period, alpha is 1/T as a basic cycle frequency, N is Rx(τα) number of points in slice component, miDenotes the value of each point, μ denotes the average value of all points, N denotes an integer from-N to N, and j denotes an imaginary number.
4. An apparatus for implementing the method for diagnosing impeller damage of centrifugal pump based on sensorless monitoring technology as claimed in any one of claims 1 to 3, comprising:
the signal acquisition module is used for acquiring transient current signals of the driving motor when the centrifugal pump operates;
the signal conditioning module is used for converting the transient current signal acquired by the signal acquisition module into a voltage signal;
the signal processing module is used for analyzing and processing the voltage signal converted by the signal conditioning module;
the storage module is connected with the signal conditioning module and the signal processing module and used for storing data;
the display module is connected with the signal processing module and used for displaying data;
and the power supply module is respectively connected with the signal acquisition module, the signal conditioning module, the signal processing module, the storage module and the display module and is used for operating the device.
5. The apparatus of claim 4, wherein: the signal acquisition module is a Hall current sensor, one interface of the signal acquisition module is connected with the signal conditioning module, and the other interface of the signal acquisition module is connected with a three-phase alternating current live wire of the centrifugal pump driving motor.
6. The apparatus of claim 4, wherein: the storage module is an SD storage card, and the display module is an LCD touch control display device.
7. The apparatus of claim 4, wherein: the signal conditioning module converts the transient current signal collected by the signal collecting module into a 0-3V voltage signal.
CN201911064918.1A 2019-11-04 2019-11-04 Centrifugal pump impeller damage diagnosis method and device based on sensorless monitoring technology Pending CN110671341A (en)

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