CN110848165A - Centrifugal pump mechanical seal fault diagnosis method and device based on sensorless monitoring technology - Google Patents
Centrifugal pump mechanical seal fault diagnosis method and device based on sensorless monitoring technology Download PDFInfo
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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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
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Abstract
The invention discloses a method and a device for diagnosing the mechanical seal fault of a centrifugal pump based on a sensorless monitoring technology, which are used for collecting transient current signals of a driving motor of the centrifugal pump, extracting the running characteristic component of the centrifugal pump by utilizing the time-frequency joint analysis of the current signals by utilizing the cyclostationary theory so as to judge whether the mechanical seal fault occurs. 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
Technical Field
The invention relates to a fluid mechanical testing method and a device thereof, in particular to a centrifugal pump mechanical seal fault diagnosis method and a device thereof.
Background
Centrifugal pumps are widely used in the industrial field. In order to ensure the efficiency and the reliability of operation, the operation state of the centrifugal pump is monitored to be very important. The common mechanical seal fault in the operation process of the centrifugal pump is the key point of the technical research on the pump operation state monitoring. The mechanical seal is composed of a rotating ring and a fixed ring, a compression element and a sealing element and is used for preventing liquid leakage. During the long-time operation of the centrifugal pump, the temperature is increased due to high rotating speed, the interface clearance is increased, and the sealing failure can be caused by pollution particles accumulated in a narrow space.
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.
The mechanical seal leakage detection device (China, publication number: 201902318U, publication date: 2011-07-20) discloses a mechanical seal leakage detection device which can perform leakage detection on a mechanical seal in advance and ensure that the mechanical seal is not leaked after being installed in a pump, but cannot perform real-time monitoring on the mechanical seal state of the pump. The technical scheme disclosed by the mechanical seal detector (China, publication number: 202522379U, publication date: 2012-11-07) does not apply a sensorless monitoring technology, is lack of reliability, only detects the sealing of the corrugated pipe, and is low in applicability. A pump head lining assembly of a vertical centrifugal pump, a mechanical seal leakage detection device and a system (China, publication number: 206329533U, publication date: 2017-07-14) disclose that whether a mechanical seal leaks or not is judged by using an output signal of a leakage detection sensor, and the leakage detection device is lack of reliability, high in maintenance cost and low in field adaptability due to the fact that the sensor is prone to interference, prone to failure and difficult to install.
Disclosure of Invention
The purpose of the invention is as follows: in view of the above problems, the present invention provides a method for diagnosing the mechanical seal fault of a centrifugal pump based on a sensorless monitoring technology, so as to improve the accuracy of the monitoring result.
The technical scheme is as follows: a centrifugal pump mechanical seal fault diagnosis method based on a sensorless monitoring technology calculates and compares relevant parameters of a centrifugal pump driving motor which operates under actual working conditions and design working conditions 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 5, extracting the passing frequency α of the blade1At 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 conditionWhen in useThe time indicates the machine seal is in fault, and the reverse indicates the machine seal is normal.
Further, step 2 specifically comprises:
(1) constructing an NxM order matrix by using the collected discrete transient current signal sequence, assuming that the signal to be measured is a discrete sequence { x (N) with a sampling interval delta T, and M is 1, 2, … }, and the reasonable period is T, determining according to the principle that the accumulated error is less than delta T/2Continuously intercepting N lines at the beginning position of the interception period to avoid the accumulation problem of the interception error, and making M equal to round (T/delta T), MkRound (kT/Δ t), k 1, 2, the sequence may be configured as a matrix:
(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:
where a is a matrix constructed by current signals, U and V are orthogonal matrices of order N × N and M × M, respectively, and Σ is diag (σ)1,σ2,…,σP) The matrix is a diagonal matrix arranged in descending order, and the diagonal elements of the matrix are singular value elements of the matrix A;
(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 characteristic information of the operation sensitivity of the centrifugal pump is decomposed into other different subspaces, so that the power grid frequency component is expressed as the decomposed first component:
(4) removal of grid frequency components in current signal AThe signal of the power frequency component in the rejection current can be obtained and expressed as:
further, in the step 3,
cyclic autocorrelation function Rx(τ, α) specifically is:
cyclic autocorrelation function Rx(τ, α) the standard deviation of the slice components is specifically:
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 the cycle period, α is 1/T as the basic cycle frequency, N is Rx(τ, α) 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.
A device for realizing the centrifugal pump mechanical seal fault 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 0-3 v 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 diagram of an apparatus for implementing the method for diagnosing the mechanical seal fault of the centrifugal pump of the present invention;
FIG. 2 is a flow chart of a centrifugal pump seal fault diagnosis method of 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 seal fault diagnosis device comprises: 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 mechanical seal fault of the centrifugal pump by the device calculates and compares the relevant parameters of the centrifugal pump driving motor 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.
(1) constructing an NxM-order matrix by using the acquired discrete transient current signal sequence, and assuming that the signal to be measured is a discrete sequence { x (N) } with a sampling interval delta T, and M is 1, 2 and …, the reasonable period is T, and the accumulated error is smallDetermining the starting position of the truncation period according to the principle of delta T/2 to continuously truncate N lines so as to avoid the truncation error accumulation problem, and enabling M to be round (T/delta T), MkRound (kT/Δ t), k 1, 2, the sequence may be configured as a matrix:
(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:
where a is a matrix constructed by current signals, U and V are orthogonal matrices of order N × N and M × M, respectively, and Σ is diag (σ)1,σ2,…,σP) The matrix is a diagonal matrix arranged in descending order, and the diagonal elements of the matrix are singular value elements of the matrix A;
(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 characteristic information of the operation sensitivity of the centrifugal pump is decomposed into other different subspaces, so that the power grid frequency component is expressed as the decomposed first component:
(4) removal of grid frequency components in current signal AThe signal of the power frequency component in the rejection current can be obtained and expressed as:
Cyclic autocorrelation function Rx(τ, α) is specifically calculated by the following equation:
cyclic autocorrelation function Rx(τ, α) the standard deviation of the slice components is calculated specifically by the following equation:
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 the cycle period, α is 1/T as the basic cycle frequency, N is Rx(τ, α) 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.
Considering the error in actual measurement, when the comparison result is 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; the comparison result is accessed by the storage module and transmitted to the display module for displaying.
Step 5, as shown in FIG. 4, extract the passing frequency α of the blade1At slice component Rx(τ,α1) And Fourier transform is carried out to obtain the amplitude value of the main frequency component, and the amplitude value A of the main frequency component under the actual working condition is recorded1Amplitude of main frequency component in fault-free normal operation under design conditionWhen the result of the comparison isIf the pressure exceeds the preset pressure, the mechanical seal is in failure, otherwise, the mechanical seal is normal; the comparison result is accessed by the storage module and transmitted to the display module for displaying.
In the step, taking the rotating speed of the centrifugal pump of 3000r/min and 6 impeller blades as an example, the basis for judging the mechanical seal fault is described. Based on the cyclostationary theory, a cyclic autocorrelation function Rx(tau, α), in the slice component corresponding to 600Hz, the frequency characteristic components indicating the occurrence and severity of the mechanical seal fault are 100Hz and 600Hz, 100Hz and 600Hz are respectively the shaft frequency and the blade passing frequency, the slice component at the blade passing frequency of 600Hz is extracted, and Fourier transformation is carried out to obtain the amplitude A of the main frequency component1The amplitude of the main frequency component is compared with the amplitude of the main frequency component when the centrifugal pump runs normally without faults under the design working condition of the centrifugal pumpAnd (6) carrying out comparison.
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. The damage of the mechanical seal can cause severe vibration of the centrifugal pump, and the analysis of the cyclostationary theory shows that radial vibration signals of 50Hz and 250Hz and a base of 350Hz are sensitive to the fault, the amplitude can be obviously increased due to the fault of the characteristic frequency in a cyclic spectrum slice, but a large amount of harmonic components still exist in a slice spectrum, and the interference can be caused to the analysis result. In contrast, the spectral line of the current signal is clearer and is suitable for fault diagnosis and analysis.
Claims (7)
1. A centrifugal pump mechanical seal fault diagnosis method based on a sensorless monitoring technology is characterized by comprising the following steps: 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 actual working conditionsStandard deviation sigma of (1), standard deviation sigma under design 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 the passing frequency α of the blade1At 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 conditionWhen in useThe time indicates the machine seal is in fault, and the reverse indicates the machine seal is normal.
2. The centrifugal pump mechanical seal fault diagnosis method based on the sensorless monitoring technology as claimed in claim 1, wherein: the step 2 specifically comprises the following steps:
(1) constructing an NxM order matrix by using the acquired discrete transient current signal sequence, assuming that the signal to be measured is a discrete sequence { x (N) } with a sampling interval delta T, and M is 1, 2 …, wherein the reasonable period is T, continuously intercepting N rows at the beginning position of the interception period according to the principle that the accumulated error is less than delta T/2 so as to avoid the problem of interception error accumulation, and making M be round (T/delta T), and M bekRound (kT/Δ t), k 1, 2, the sequence may be configured as a matrix:
(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 can be constructed so that the characteristic information in matrix A is decomposed to be orthogonalVector ui、viA series of subspaces are formed:
where a is a matrix constructed by current signals, U and V are orthogonal matrices of order N × N and M × M, respectively, and Σ is diag (σ)1,σ2,…,σP) The matrix is a diagonal matrix arranged in descending order, and the diagonal elements of the matrix are singular value elements of the matrix A;
(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 characteristic information of the operation sensitivity of the centrifugal pump is decomposed into other different subspaces, so that the power grid frequency component is expressed as the decomposed first component:
(4) removal of grid frequency components in current signal AThe signal of the power frequency component in the rejection current can be obtained and expressed as:
3. the centrifugal pump mechanical seal fault diagnosis method based on the sensorless monitoring technology as claimed in claim 1, wherein: in the step 3, the step of the method is that,
cyclic autocorrelation function Rx(τ, α) specifically is:
cyclic autocorrelation function Rx(τ, α) the standard deviation of the slice components is specifically:
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 the cycle period, α is 1/T as the basic cycle frequency, N is Rx(τ, α) 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. A device for realizing the method for diagnosing the mechanical seal fault of the centrifugal pump based on the sensorless monitoring technology as claimed in any one of claims 1 to 3 is characterized by comprising 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.
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.
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CN115015756A (en) * | 2022-07-14 | 2022-09-06 | 深圳市文浩科技有限公司 | Fault diagnosis method for fine-crushing fused new material mixer |
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EP1495773A2 (en) * | 2003-07-07 | 2005-01-12 | Terumo Corporation | Centrifugal fluid pump apparatus |
CN101592590A (en) * | 2008-05-26 | 2009-12-02 | 唐德尧 | A kind of fault indirect diagnosis technique of rotating blade |
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